MANUAL PJ-8 Operating and Services Manual

8/12/2019 MANUAL PJ-8 Operating and Services Manual

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GARDNER DENVER@ 3-l-6052nd EditionApril, 1998

TRIPLEX PLUNGER PUMP

MODEL

PAH

OPERATING ANDSERVICE MANUAL

Gardnerdenver


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MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITHGENUINE GARDNER DENVER

PARTS AND SUPPORT SERVICES

Gardner Denver@ and OPI@ genuine pump parts aremanufactured to original tolerances and designed foroptimum dependability. Design and material innova-

gency parts by direct access to the Gardner DenverMachinery Inc. Master Distribution Center (MDC) inMemphis, Tennessee.

tions are the result of years of experience with

hundreds of different pump applications. Reliability inmaterials and aualitv assurance are incorporated in our

Your authorized distributor can support your GardnerDenver and OPI pump needs with these services:

genuine replacement parts. 1. Trained parts specialists to assist you in select-ing the correct replacement parts.

Your authorized Gardner Denver and OPI distribu-tor offers all the backup youll need. A worldwidenetwork of authorized distributors provides the finest

Repair and maintenance kits designed with thenecessary parts to simplify servicing your pump.

product support in the pump industry.

Your local authorized distributor maintains a large in-ventory of genuine parts and he is backed up for emer-

Authorized distributor service technicians are factory-trained and skilled in pump maintenance and repair.They are ready to respond and assist you by providingfast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pagesof your phone directory or contact:

Distribution Center:Gardner Denver Machinery Inc.Master Distribution Center5585 East Shelby DriveMemphis, TN 38141Phone: (901) 363-6100Fax: (901) 363-l 095

Factory:Gardner Denver Machinery Inc.1800 Gardner ExpresswayQuincy, IL 62301Phone: (217) 222-5400Fax: (217) 224-7814

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL andSERIAL NUMBER (see nameplate on unit). The SerialNumber is also stamped on top of the cylinder end ofthe frame (cradle area).

per unit, quantity is indicated in parenthesis. SPECIFYEXACTLY THE NUMBER OF PARTS REQUIRED.

DO NOT ORDER BY SETS OR GROUPS.

All orders for Parts should be placed with the near-est authorized distributor.

To determine the Right Hand and Left Hand side of apump, stand at the power end and look toward the fluidend. Right Hand and Left Hand are indicated in paren-

Where NOT specified, quantity of parts required per thesis following the part name, i.e. (RH) & (LH), whenpump or unit is one (1); where more than one is required appropriate.

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Gardner Denver@ and OPI@ pumps are the result of advanced engineering and skilled manufacturing. To be assuredof receiving maximum service from this machine the owner must exercise care in its operation and maintenance.This book is written to give the operator and maintenance department essential information for day-to-day opera-tion, maintenance and adjustment. Careful adherence to these instructions will result in economical operation andminimum downtime.

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

A WARNING

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

CAUTION

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

NOTICE

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

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TABLE OF CONTENTS

Maintain Pump Reliability and Perform ance with Genuine Gardner Denver@ Partsand Support Services ..................................................................... i

Instructions for Ordering Repair Parts ....................................................... i

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

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

Section1,DangerNotices.. ............................................................... .

Section 2, Installation & Operating Instruct

Sectional View of PAH Put1

Section 3, Service Instruct I

Ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

uid Cylinder.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9p With Block F

ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3

Section 4, Trouble Shooting ..............................................................

Section 4, Dimensions & Running Clearances .............................................. 27

Recommended Torques.. .............................................................. ..2 8

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

For Parts List see:

PARTS LIST # 3-l-522

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Bearing and Eccentric Assembly ............... 17

Connecting Rods ............................. 17

Covers and Guards, Danger Notice .............. 2

Crankcase Oil Requirements .................. 25

Crossheads and Pins ......................... 18

Cylinder ..................................... 12

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

Danger Notices

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

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

Flammable , Hot, Cold or Corrosive FluidPumping ............................... 4

Hammer Lug Fasteners ..................... 1

High Pressure Liquid Jetting, Blasting andCleaning ............................... 5

Hydraulic .................................. 2

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

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

Wedge Puller .............................. 2

DIMENSIONS & RUNNING CLEARANCES,SECTION 5 ............................... 27

Drilling and Well Service Valves ................ 12

Eccentric and Bearing Assembly ............... 17

Equipment Moving and Lifting, Danger Notice ..... 2

Figure 1 - Sectional View of PAH Pump ......... 11

Figure 2 - Block-Type Fluid Cylinder for WaterFlood Service ............................. 12

Figure 3 - Jackshaft Bearing Detail ............. 16

Figure 4 - Jackshaft Bearing Installation ........ 16

Filter, Oil .................................... 10

Flammable, Hot, Cold or Corrosive Fluid Pumping,Danger Notice ............................. 4

Gears, Main ................................. 18

Hammer Lug Fasteners, Danger Notice .......... 1

Heat Exchanger .............................. 10

t high Pressure Liquid Jetting, Blasting and Cleaning,Danger Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

t hydraulic Puller, Danger Notice . . . . . . . . . . . . . . . . . 2

I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

NSTALLATION AND OPERATING INSTRUC-TIONS, SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . 7

Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Lifting and Moving Equipment, Danger Notice . . . . . 2

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Lubrication ................................... 8

Lubricator ................................... 14

Main Gears .................................. 18

Moving and Lifting Equipment, Danger Notice ..... 2

Oil Filter ..................................... 10

Oil Pump.. ................................... 9

Oil Stop Heads ............................... 18

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

Piston Liners and Liner Clamps ................ 14

Piston Rod .................................. 14

Piston Washing System ....................... 14

Pistons ..................................... 14

Plunger ..................................... 13

Plunger Packing, Lubrication Recommendation . . 26Rock Drill Lubricants ....................... 26

Steam Cylinder Oils ....................... 26

Plunger Stuffing Box Packing .................. 13

Power End .................................. 16

Pressure Relief Valve .......................... 7

Pressurized Pump Systems, Danger Notice ...... 3

Pump,Oil .................................... 9

Push Rods .................................. 18

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

Running Clearances, Recommended ........... 27

SERVICE INSTRUCTIONS, SECTION 3 ........ 12

Service Instructions ........................... 16

Power End ............................... 16

Slow Speed Operation of Well-Servicing Pumps . . 9

Starting a New Pump .......................... 8

Suction System ............................... 7

Torques, Recommended ...................... 28

TROUBLE SHOOTING, SECTION 4 ............ 20

Valve Seat Pulling, Danger Notice ............... 2

Valves .................................... 12

Drilling and Well Service ................... 12

Water Flood Service ....................... 12

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

Water Flood Service Valves .................... 12

Wedge Puller, Danger Notice ................... 2

Well-Servicing Pumps, Slow Speed Operation .... 9


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SECTION 1DANGER NOTICES

DANGER

Read and understand the following DANGERNOTICES before moving or operating the pump or anypump package unit equipment.

Reciprocating pumps are machines capable of produc-ing high fluid pressures and flow rates and are de-signed to be used with proper care and caution bytrained, experienced operators. TO AVOID PER-SONAL INJURY, DEATH AND/OR EQUIPMENTDAMAGE, READ AND THOROUGHLY UNDER-STAND THE FOLLOWING DANGER NOTICESPLUS THE ENTIRE OPERATING AND SERVICEMANUAL BEFORE ATTEMPTING TO MOVE OROPERATE THE PUMP. Contact a Gardner Denver

Machinery service representative if you are unable tocomply with any of the danger notices or proceduresdescribed in these documents.

Closely examine the data plate upon pump delivery tobecome thoroughly familiar with the operating limits forthis pump model. The pump must never be operatedat speeds, pressures or horsepower exceeding themaximum values shown on the data plate or atspeeds below the minimum shown. Failure to ob-serve the operating limits shown on the data platecould result in personal injury, death, and/orequipment damage and will void the warranty. Al-terations to the pump, or application of the pump out-side the data plate limits, must not be made withoutGardner Denver Machinery written approval togetherwith a new data plate, as dangerous operating condi-tions could result.

THE DANGER NOTICE AND DATA PLATES PRO-VIDED ON THE EQUIPMENT MUST NOT BE RE-MOVED, PAINTED OVER, HIDDEN OR DEFACED.They must be replaced if they become damaged or un-readable. Provisions should be made to have the fol-lowing written danger notices plus the pump operatingand service manual readily available to operators andmaintenance personnel. In addition, copies of all pump

system accessory component (e.g. pressure reliefvalve, pulsation dampener, suction stabilizer, engine,electric motor, etc.) operating and service manualsshould be readily available for operator and mainte-nance personnel use. Read and follow all the precau-tions and instructions contained in these manuals. Ifany of these documents are lost or become illegiblethey must be replaced immediately. The danger no-tices plus the operating and service manuals should bereread periodically by both operators and maintenance

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personnel to refresh their memories in safe proceduresand practices.

Keep in mind that full operator attention and alertness

are required when operating high pressure pumpingequipment. Operators should not begin or continue op-erations when tired, distracted or under the influence ofalcohol or any type of prescription or nonprescriptiondrugs.

The timely replacement of expendable parts and anyother worn or damaged parts can prevent equipmentdamage and possible injury. The original parts used inGardner Denver pumps are designed and tested to ex-acting standards to provide high quality performanceand durability. Your best insurance in maintainingthese characteristics is to use genuine Gardner Denverreplacement parts.

A broad range of danger notices are covered on thesepages, however, they cannot substitute for training, ex-perience and common sense in the safe operation ofhigh pressure pumping equipment.

HAMMER LUG FASTENERS

dANGER

On pumps or pump package units equipped with ham-mer lug connectors and/or hammer lug valve coversthe following precautions must be observed to avoidpersonal injury, death and/or equipment damage due

to contact with the hammer, hammer bar, broken partsfrom the hammer, hammer bar or lugs or other objectspropelled by hammer blows. When tightening or loos-ening hammer lug connectors and valve covers, opera-tors or maintenance personnel should:

Inspect the hammer, hammer lugs and hammerbar, if one is used, to insure they are all in goodcondition. Replace any of these parts which arecracked, damaged or badly worn.

Wear safety shoes and goggles.

Alert other personnel to move away from thearea.

Check to insure they have safe footing.

Fully engage the hammer bar, if one is used, toprevent it from disengaging violently from thecover as a blow is struck.

Wipe their hands and the hammer handle andmaintain a firm grip on the handle to avoid losingcontrol of the hammer while swinging and strik-ing.

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l Carefully swing the hammer to avoid strikingthemselves, another person and objects otherthan the targeted lugs or hammer bar.

Avoid swinging the hammer above shoulderheight.

VALVE SEAT PULLING

DANGER

The following precautions must be observed by opera-tors and maintenance personnel to avoid personal inju-ry, death and/or equipment damage from contact withthe puller, hammer, wedge or broken parts from thesecomponents when using either a hydraulic or wedgevalve seat puller:

Hydraulic Puller

Wear safety shoes and goggles.

l Chain or tie the jackdown as it will jump violentlywhen the valve seat disengages from the valvedeck.

l Check to insure the pressure applied by the hy-

Covers and guards are intended to not only protectagainst personal injury or death, but to also protect theequipment from damage from foreign objects.

EQUIPMENT MOVING AND LIFTING

DANGER

draulic pump does not exceed theram maximum pressure rating.

Wedge Puller

hydraulic

Heavy equipment including pumps, pump packageunits and components should only be moved or liftedby trained, experienced operators, who are physicallyand mentally prepared to devote full attention and alert-ness to the moving and lifting operations. An operatorshould be fully aware of the use, capabilities, andcondition of both the equipment being moved and theequipment being used to move it.

l Grind off any mushroomed materialwedge before use.

DANGER

Failure to follow safe and proper

pump, pump package or componentlifting or moving procedures can leadto personal injury, death and/orequipment damage from shifting, fal-ling or other unexpected or uncon-trolled equipment movements.

from the

Follow the danger notices listed above in thehammer lug section, but substitute the termwedge for hammer lug and hammer bar.

Make sure the hoist, lift truck, ropes, slings, spreader,or other lifting equipment you are using is in good condi-tion and has a rated lifting capacity equal to or greaterthan the weight being lifted. Lifting devices must bechecked frequently for condition and continued confor-mance to rated load capacity. They should then betagged with the inspected capacity together with thedate of inspection.

COVERS AND GUARDS

DANGER

All pump covers must be securelyfastened in proper position at alltimes when the pump is operating toavoid personal injury or death frommoving parts. In addition, all moving

parts on the entire pump package, in-cluding but not limited to engine ormotors, drive shafts, belts, chains,pulleys, gears, etc., must be equippedwith guards or covers, which mustalso be securely fastened in properposition at all times when the equip-ment is operating.

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Fully assembled pumps and pump package units areheavy and should only be moved using the specifiedlifting lugs or attachments. Many individual compo-nents have lifting eyes or lugs which must not beused to lift assemblies, as they are designed tobear the weight of the component only. Before lift-ing the individual component check to insure the liftingattachment is firmly secured to the component with un-damaged, properly torqued fasteners, sound welds, orother secure attachments. Examine the lifting eyes,lugs, slots, holes or other projections to insure they arenot cracked, otherwise damaged or badly worn. Therepair of existing or addition of new welded lifting eyes,lugs or other projections should only be performed byexperienced, qualified welders.

Package units should be lifted with spreaders con-nected to the lifting attachments normally built into thepackage unit support skid. Packages too large to lift ful-ly assembled should be separated into smaller loads.

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For these smaller loads the lifting devices should befastened to the lifting attachments normally built intothe individual motor, engine, pump or transmission/torque converter, or their separate support skids.

When lifting subassembled components, for examplea suction stabilizer attached to suction piping or a dis-charge pulsation dampener attached to a strainer crossand piping, use special lifting slings designed to safelysupport the combined weight of the components.

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

When you start to lift a pump, package unit, subassem-blies or individual components and you observe theequipment is tilting, or appears unbalanced, lower theequipment and adjust the lifting device to eliminatethese improper lifting conditions before proceeding tomove the equipment.

It is poor practice and dangerous to allow the equip-ment to pass over or close to your body or limbs. Beprepared to move quickly out of danger if equipmentstarts to fall, slip or move unexpectedly toward you.

PRESSURIZED PUMP SYSTEMS

DANGER

Fluids under high pressure can pos-sess sufficient energy to cause per-

sonal injury, death and/or equipmentdamage either through direct contactwith escaping fluid streams or by con-tact with loose objects the pressur-ized fluid propels.

Operating a pump against a blocked or restricted dis-charge line can produce excessive pressures in the en-tire discharge system, which can damage or burst dis-charge system components.

DANGER

Never operate a pump without a prop-erly sized pressure relief valve lo-cated in the flowing discharge line im-mediately adjacent to the pump dis-charge connection.

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The relief valve should be placed in the flowing dis-charge line and not at the opposite end of the dischargemanifold in a dead end connection. The dead end maybecome c logged with solid material carried in the fluid,which could prevent proper relief valve operation.

DANGER

Never place a shut-off valve or anyother component between the pumpdischarge connection and the pres-sure relief valve.

Make sure the pressure relief valve is installed so anypressurized relief discharge from the valve is directedaway from possible contact with people or equipment.The relief valve must be set to relieve at a pressureequal to or below the maximum pressure values shownon the pump data plate. However, if a component isused in the discharge system with a lower rated pres-sure capability than that listed on the pump data plate,the pressure relief valve must be set to relieve at a pres-sure equal to or below the rated capability of the lowestrated component.

Before starting the pump every time, check to in-sure:

The pressure relief valve is in good operatingcondition and has been set to the proper reliefpressure.

Any pipe line used to direct pressurized relief

flow to another location, such as a collectingtank, is not blocked.

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

Check all fluid end discharge system componentsincluding pipe, connections, elbows, threads, fas-teners, hoses, etc., at least once every six monthsto confirm their structural adequacy. With time,wear, corrosion and fatigue can reduce the strength ofall components. Magnetic iron and steel componentsshould be checked with magnetic particle or dye pene-trant crack detection equipment. Nonmagnetic materi-als should be checked for cracks with dye penetrants.All metallic components should also be visuallychecked during these inspections for signs of corro-sion. If a component shows evidence of cracking orloss of material due to corrosion it must be replacedwith a new part.

Continually monitor suction and discharge hose as-semblies when the pump is operating for leakage, kink-ing, abrasion, corrosion or any other signs of wear ordamage.

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Worn or damaged hose assemblies should be re-placed immediately. At least every six months ex-amine hose assemblies internally for cut or bulgedtube, obstructions and cleanliness. For segment stylefittings, be sure that the hose butts up against the nippleshoulder, the band and retaining ring are properly setand 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 lay-line of the hose to be sure that the assembly is nottwisted. Cap the ends of the hose with plastic coversto keep them clean until they are tested or reinstalledon the pump unit. Following this visual examination,the hose assembly should be hydrostatically tested, ontest stands having adequate guards to protect the oper-ator, per the hose manufacturers proof test procedure.

Fluid end component inspections should be per-formed more frequently than every six months ifpressures above 2500 psi are used in the dis-charge system or if corrosive, flammable or hot(over 110 F) fluids are being pumped.

Proper stuffing box packing selection is important forsafe pump operation. Contact a Gardner Denver Ma-chinery service representative for assistance in select-ing the proper packing before beginning operation.

Before starting the pump for the first time and periodi-cally thereafter check the pump, suction and dischargesystem fastener torques versus the values listed in theOperating and Service Manual tables to insure propertightness. Over and under torquing can damagethreaded pipes, connections and fasteners, which maylead to component damage and/or failure. Replace all

components found to be damaged or defective. Onpumps equipped with stuffing boxes, the gland must beengaged by at least three (3) threads to hold the dis-charge pressure of the pump.

DANGER

Do not attempt to service, repair, ad-just the plunger packing or otherwisework on the pump while the unit is op-erating. Shut off the pump drive mo-

tor or engine and relieve the fluidpressure in the pump suction and dis-charge systems before any work orinvestigation is performed on thepump or pump systems.

Block the crankshaft fro m turning and make certain thatall pump drive motor or engine start switches or starter

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controls are clearly tagged with warnings not to startthe pump while repair work is in process.

Whenever the pump is operating, continually monitorthe entire suction, discharge and pump lubricating sys-tems for leaks. Thoroughly investigate the cause forleakage and do not operate the pump until the causeof the leak has been corrected. Replace any partswhich are found to be damaged or defective. When agasketed joint is disassembled for any reason, discardthe used gasket and replace it with a new, genuine Gar-dner Denver gasket before reassembling the joint.

Due to the high working pressures contained by thefluid cylinder, discharge manifold and discharge piping,welding on these components is not recommended. Ifwelding on the discharge system cannot be avoided,only experienced, qualified welders should be used. Inaddition, the welded part should be hydrostaticallyproof tested in the shop with water or hydraulic fluid toone and one half times maximum discharge systemworking pressure, with no observable fluid leakage, be-fore the part is reinstalled in the pump system.

In summary, high pressure fluid streams can possesssufficient energy to cause personal injury, death and/orequipment damage. These results can occur eitherthrough direct contact with the fluid stream or by con-tact with loose objects the fluid stream has propelled,if the pump system is improperly used, or if the fluid ismisdirected, or allowed to escape from defective or im-properly maintained equipment.

FLAMMABLE HOT, COLD OR CORROSIVE FLUIDPUMPING

DANGER

Extreme caution must be exercisedby trained and experienced operatorswhen flammable, hot, cold or corro-sive fluids are being pumped, in orderto avoid personal injury, death and/orequipment damage due to explosion,fire, burn, extreme cold or chemicalattack.

Never operate a pump which is pumping hydrocarbonsor other flammable, hot, cold, or corrosive fluids whenany part of the pump, suction system or discharge sys-tem is leaking. Stop the pump immediately if any leak-age, other than a few drops per minute of packingweepage, is observed. Keep all flame, sparks, or hotobjects away from any part of the pump, suction sys-tem, or discharge system. Shield the pump, suction

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system and discharge system to prevent any flam-mable, hot, cold or corrosive fluid leakage from drippingor spraying on any components, flame, sparks, hot ob-jects or people. Inspect the plungers, packing, gasketsand seals for fluid leakage frequently and replace allworn or leaking parts.

Selection of the proper gaskets, seals and stuffing boxpacking is even more critical when flammable, hot, coldor corrosive fluids are being pumped than when other,inherently less dangerous fluids are used. Contact aGardner Denver Machinery service representative forassistance in selecting the proper gaskets, seals andpacking before beginning operation.

Since some packing seepage into the cradle area is in-evitable, the drain at the bottom of the cradle must beconnected to a drain line which conducts the fluid leak-age to a collection container located in a protectedarea. The entire drain system and container must beconstructed of materials resistant to attack from thepumped fluid or from explosion or fire of the pumpedfluid. Heavy duty cradle covers must be securelyfastened in the proper position on the pump at alltimes when the pump is operating. If the pumpedfluid releases harmful, explosive or flammable va-pors the covers must be vented to conduct thefumes away from the pump unit to a nonhazardousarea.

Before beginning pumping operations or starting thepump power source (whether an engine or electric mo-tor) check the atmosphere all around the pumping sitefor the presence of flammable or explosive vapors. Donot begin operation and stop ongoing operation if flam-mable or explosive vapors are detected. Hot surfaces,sparks, electric current or engine exhaust could igniteflammable or explosive vapors. Each engine used asa power source on pumping units where flammable orexplosive vapors could form should be equipped withan air inlet shut-off. If flammable or explosive vaporsare present in the pumping site atmosphere, an enginecould continue to run on these vapors even after the en-gine fuel line is shut-off if an air inlet shut-off is notused.

In addition, on pumping units used where flammable orexplosive vapors could form, all electric motors used aspower sources must be of explosion proof constructionand all electrical components and wiring must meet thecurrent National Electrical Code for explosive atmosp-heres.

These precautions must be taken to avoid possible per-sonal injury, death and/or equipment damage from ex-plosion, fire or burns.

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HIGH PRESSURE LIQUID JETTING BLASTINGAND CLEANING

dANGER

Extreme caution must be exercised ifany type of wand, gun, nozzle or anyother pressure and flow directing de-vice is attached to the pump dis-charge system for use in jetting,blasting, cleaning, etc. This type ofequipment must be used with utmostcare by trained, experienced opera-tors. High pressure fluid streams caneither by direct contact or by propel-ling loose objects, cause serious per-sonal injury or death to the operatorsand/or other persons.

Pressure or flow directing devices often receive pres-surized flow through flexible hoses, which can burst ifthey are kinked, cut, abraded or are otherwise worn,damaged or pressured above their rated capacity. Pro-tect the hose and connections from damage by people,objects and vehicles. A broken, cut or otherwise bursthose can release pressurized fluid which may causepersonal injury, death and/or equipment damage.

High pressure fluid from hand held or hand directedpressure and flow directing devices may overpower anoperators ability to control or direct the device, which

could lead to personal injury, death and/or equipmentdamage. The operator must brace against the back-ward thrust of a hand held device. In addition, a safetyharness or safety net must be used when working in anarea where the operator could be injured in a fall. Standto the side of any tubing or container being sprayed toavoid back spray and never operate a hand held deviceabove shoulder level.

Never direct the pressurized fluid stream at yourself orany other person, control valves, the pump, pumpdrive, suction or discharge systems. The pressurizedstream can cause serious personal injury or death andcan also change valve or control settings which could

dangerously increase the delivery pressure to the pres-sure and flow directing device.

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

Check to insure this automatic shut-off equipment isoperating properly before every use and never circum-

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vent the automatic shut-off for any reason or by anymeans when operating the equipment.

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

Full operator attention and alertness are required whenoperating this equipment to avoid personal injury, deathand/or equipment damage. The operators should takefrequent rest breaks and cease operations when theybecome tired or distracted.

Before the equipment is started, the work area must beinspected and properly prepared to avoid personal inju-ry, death and/or damage to equipment. Make sure thework area is checked for hazardous fumes, has ade-quate ventilation for engine exhaust and sufficientdrainage for released fluid. Check the work area forelectrical equipment, connections, outlets, fixtures, orlines. If any are present they must be made water tightand the electrical power to these devices must be shutoff to avoid electrical shocks from fluid contact. Thework area should be clearly marked and roped off tokeep unauthorized people and vehicles from entering.Remove all loose parts, tools and equipment from thework area before beginning operation.

All pressure containing devices including wands,nozzles, guns, hoses, connections, etc., should be reg-ularly checked for condition. These componentsshould all be tagged with their tested pressure capabili-ties together with the date testing was performed. Al-ways be aware of the pressure level in the systemand never connect any equipment to the systemwhich has a rated or tested pressure capability be-low the system operating pressure. The equipmentmust be shut down and the system pressure releasedbefore changing or disconnecting wands, nozzles,

guns, hoses, connections or any other pressurizedsystem components.

All pressure containing devices including wands,nozzles, guns, connections, etc., plus all automaticshut-off, pressure and control equipment should betreated with care. Protect them from damage bypeople, objec ts and vehicles. Never lay them in dirt,mud, ice or other loose material which could plug thefluid opening or interfere with their operation. Neveruse the wand, nozzle, gun, etc. to pry loose material offitems being cleaned.

Before starting operation in a cold environment, checkto make sure there is no ice in the fluid system and re-peat this inspection each time before operation is re-started.

Before purchasing wands, nozzles, guns, connections,and hose, etc., manufacturers of these componentsshould be contacted for detailed information on the de-sign and safety features incorporated in their products.After careful study of various manufacturers products,we recommend that only those wands, nozzles, guns,connections and hose, etc., be considered for pur-chase that you judge to offer the highest quality of de-sign, construction and safety, since these componentsare among the most critical to the safe operation of highpressure liquid jetting, blasting and cleaning equip-ment.

After you have selected and purchased these compo-nents, follow the manufacturers instructions complete-ly in their use.

In summary, high pressure jetting, blasting andcleaning are inherently dangerous, as the pressur-es and flow rates needed to remove scale, clean,etc. are sufficient to cause personal injury, deathand/or equipment damage resulting from, but notlimited to, any of the conditions described in theabove Danger Notices.

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SECTION 2INSTALLATION & OPERATING INSTRUCTIONS

DANGER

Always wear safety shoes andgoggles when operating and perform-ing maintenance on a pump to helpprevent personal injury to eyes andtoes from pressurized fluids and fal-ling or flying objects.

INSTALLATION - The pump should be located asclose to the fluid supply as possible. A short, s traightsuction line will provide the best pump performanceand reduces the possibility of cavitation.

The pump must be driven in the direction indicated byarrows on the frame, that is, the eccentric must rotateover center toward the crosshead oil trough. Rotationin this direction is necessary to assure adequate cross-head lubrication.

Adequate space should be provided around the pumpfor ease of inspection and service. The pump must beleveled and checked for gaps under all frame feet.Shim any gaps to prevent frame damage when the feetare securely fastened to the foundation or base. Pumpframe damage may also occur on truck mounted unitsdue to truck frame flexing, unless a stiff base or isola-tors are used between the pump and truck frames.

The maximum allowable temperature of the pumpedfluid is 200' F. (93 C.). Any pump application over thistemperature, or with a suction pressure over 50 psi,must be approved in writing by Gardner Denver Ma-chinery Marketing.

SUCTION SYSTEM - Suction system conditions arecritical to proper pump performance and durability. Ad-equate suction pressure must be provided at the pumpsuction connection.

The suction pipe or hose should be the full size of thepump inlet opening. If the suction line is relatively long,

the next larger size pipe or hose should be used. Thesuction line should have a very slight, constant upwardgrade toward the pump to insure air pockets do notform in the line. The suction line must also be air-tight.Both air pockets and air leaking into the line will reducethe pump volumetric efficiency and produce shockloading inside the pump. Any bends in the suction lineshould be long radius sweeps. All piping must be sup-ported independently of the pump to insure that nostrain is imposed on the pump by misalignment, vibra-

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tion or improperly fitted pipe. Any suction line shutoffvalve(s) must be full opening to avoid choking thePump.

A wARNINGIf a suction line strainer is used, itmust be cleaned frequently, as aclogged strainer can cause pump ca-vitation and damage.

Many potential pumping problems can be avoided byreviewing the proposed pump layout and suction condi-tions with Gardner Denver Machinery Marketing beforea pump is purchased.

PRESSURE RELIEF VALVE -The pump must be pro-tected from excess pressure by a pressure relief valve.This valve must be properly sized to handle the full flowof the pump and must be installed as close to the pumpdischarge connection as possible.

DANGER

Never install a shutoff valve in the linebetween the pressure relief valve andthe pump cylinder. Pumping againsta closed valve could produce pres-sures sufficient to cause propertydamage and/or serious personal inju-ry or death.

DANGER

Improper use or maintenance of reliefvalves can cause excessive pressurewhich may result in property damageand/or serious personal injury ordeath.

The relief valve should be set to operate at approxi-mately 1.1 times the discharge pressure, but MUSTNOT exceed equipment tolerances and ratings.

Check the valve for proper functioning at least once amonth.

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STARTING A NEW PUMP - Pumps are shipped fromthe factory without oil in the crankcase. The hoodshould be removed and the power end examined andcleaned if necessary. The pump may have been in stor-age or in the yard for some time and as a consequence,dirt or rust from condensation may have formed in thecrankcase. Also, parts may have been robbed from thepump during storage and not replaced. All nuts and

screws should be tightened. Fill the crankcase with thequantity of oil shown on the nameplate attached to thepump frame. Refer to the lubrication data plate and thismanuals LUBRICATION section for the proper oilspecification.

Be sure all valves in the discharge line are open. Novalves should be installed between the pump and pres-sure relief valve in the discharge line.

To prevent excessive wear on the fluid pistons andpacking when starting, remove a suction valve coverplate on each side of the fluid end and prime the pump.The pump should be started slowly, if possible, and

should be operated for several hours with practically nodischarge pressure.

Make certain the pump is rotating in the correct direc-tion. The direction of rotation of the jackshaft is indi-cated by an arrow on the frame.

A WARNINGPumps are shipped from the factorywithout oil in the crankcase.

DANGER

The cradle cover, all guards and in-spection plates must be securely fas-tened in the proper position beforethe pump is started and must not beremoved at any time when the pumpis in operation, to avoid personal inju-ry and/or death from moving parts.

A WARNINGThe pump must be primed at start-upto prevent damage to packing andplungers.

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The oil level on PAH model pumps should be checkedwith the pump running. The running level on thesepumps should be between the middle and top of thesight glass in the oil level indicator, located on the sideof the pump frame. Add oil through the threaded open-ing where the breather is mounted to the hood. Thepump may then be brought up to working speed andpressure. Check for overheating and listen for abnor-

mal noise. Inspect all joints in the suction line to be surethere are not air or fluid leaks. Check for excessivevibration caused by improper suction conditions. Besure the stuffing box packings are properly lubricatedper the directions given in the packing lubricator sec-tion. If equipped with piston and liner, be sure liner/pis-ton wash system is operating properly.

LUBRICATION -The eccentric, crossheads, connect-ing rods and main bearings are lubricated by oil in thecrankcase.

AWARNING

Use only extreme pressure, API GL-5gear oil, having the required additivesand viscosity, in the crankcase. Theuse of motor oils in the crankcasedoes not provide acceptable lubrica-tion and voids the warranty.

The selected API GL-5 oil must have anti-wear, anti-foaming, noncorrosive and rust inhibiting additives. Alist of recommended grades vs. temperatures is lo-cated in the back of this manual and on the pump lu-brication data plate. The list is based on premium quali-ty oils having viscosity values that do not exceed 7000SSU at the minimum start-up oil temperatures listedand viscosity values between 1500 SSU and 200 SSUfor the crankcase oil temperatures listed. Oils with vis-cosity values significantly different from these values,at the temperatures listed, may be too thick a t low tem-peratures to flow into close bearing clearances, or maybe too thin at high temperatures to carry the requiredloads. In either case, pump damage could occur.

If a 7000 SSU maximum viscosity at start-up cannot beassured, a crankcase heater is required. Also, if crank-case oil temperature exceeds 200 F (93 C), an oilheat exchanger with a circulating pump is required toprevent seal damage and oil break down.

For outdoor operation, the multiviscosity oils are pre-ferred to provide acceptable lubrication over wide tem-perature ranges. However, when multiviscosity oils arenot available, straight weight oils should be acceptable,if care is taken to stay within the listed temperatureranges. Straight weight oils are also ideal in pumps

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used indoors, when ambient temperatures are con-trolled.

The oil level in the pump should be checked frequently.Add oil through the breather opening. The breather canbe removed by rotating it counter clockwise. Keep thebreather tightly in place while the pump is operating toprevent moisture and dirt from entering the crankcase .On pumps equipped with a replaceable filter elementtype breather, clean the element frequently and replacethe element every six months. When operating in verydusty or dirty conditions, more frequent replacementmay be necessary.

The pressure gauge must be watched and if it showslack of pressure, the oil level should be checked. Thescreen on the suction of the circulating pump might bestopped up so the pump cannot get sufficient oil tomaintain pressure. This screen should be examined atrather frequent intervals and thoroughly cleaned. It canbe removed without draining the oil from the crankcase .

When overhauling the pump, check all oil connectionsand clean the lines thoroughly. The oil relief valveshould also be inspected.

If the pump is to be stored or shut down for an extendedperiod and if oil regularly used does not contain an addi-tive for rust prevention, drain the oil from the crankcaseand add an oil base rust preventative, then turn thepump over a few times to coat working parts. This willprotect the power end parts against dam age by rust.Before the pump is again placed in operation, drain thecrankcase and fill with new oil.

The time between oil changes depends on the pumplocation and operating conditions. Ordinarily, if thecrankcase is kept closed, the normal change interval is1000 hours. However, the oil must be changed anytime water or other contamination is found in the oil.

A WARNINGThe oil should be checked for con-tamination whenever pumped fluidsprays or splashes against an oil stophead. This is especially critical when

the fluid contains salts or solids, asthese contaminants can plug lubri-cating passages and cause rapidpower end failure.

On pumps equipped with a magnetic drain plug, checkthe magnet for metal chips whenever the oil is drained.If chips are found, remove the frame end plate and the

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plugs over the crosshead oil reservoir. Clean and flushthe crankcase through these openings before adding afresh oil fill.

Some operating conditions and/or oil brands produceexcessive oil foaming, even when the specified GL-5oils containing anti-foaming additives are used. Oilfoaming can cause pum p damage, as oil bubbles willnot lubricate moving parts properly. If significant oilfoaming occurs, contact Gardner Denver MachineryMarketing or Service for the current factory recom-mended defoamant to be added to the lubricating oil.When it is not possible to contact Gardner Denverpeople, a small amount of kerosene added to the oil willusually reduce foaming. One half of a fluid ounce ofkerosene added to each gallon of oil should be suffi-cient to control foaming. The use of larger amounts ofkerosene per gallon of oil will reduce the oil viscosity,which could result in rapid pump wear and failure.

OIL PUMP - The oil pump is the gear-driven rotarytype pump which provides filtered oil under pressure to

connecting rod liners and crosshead pin bushings.Crossheads and guides are lubricated by flood from thegear. The pump is reversible and will deliver oil regard-less of the direction of rotation. All the oil pumped is fil-tered before it goes to the bearings.

Slow Speed Operation of Well-Servicing Pumps -When a PAH well servicing pump is operated below100 RPM, special auxiliary oil pump and piping must beinstalled to maintain adequate lubrication. Oil pressureof 25 PSI minimum must be maintained at all times.The auxiliary oil pump should have a capacity of 15 gal-lons per minute.

A 1 WARNING

Do not operate PAH Well ServicingPump below 34 RPM.

A f WARNING

Do not operate PAH Drilling ServicePump below 60 RPM.

OIL FILTER -A replaceable element oil filter is locatedinside the pump crankcase. The filter mounting flangeis on the outside, making it possible to replace the ele-ment by removing the end plate. Only the oil within thefilter case will be spilled when the element is withdrawn.

The filter element should be replaced each time thecrankcase oil is changed or every 1000 hours.

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The filter element is protected from excessive internaloil pressure by a relief valve between it and the oilpump. The relief valve setting is 110 PSIG (7.73 kg/cm2).

On heat exchanger equipped pumps, oil flows throughthe oil filter before going through the heat exchanger.

HEAT EXCHANGER - A bronze water/oil heat ex-changer is standard equipment on PAH pumps fur-nished for 275 HP drilling service. The heat exchangermaintains crankcase oil temperature at 160 F (71 C)maximum.

PAH pumps furnished for 310 HP well servicing do notinclude a heat exchanger. Since PAH pumps aresometimes changed from one type of service to theother, each pump is equipped with two name plates.One plate lists the 310 HP intermittent well service rat-ings and the other lists the 275 HP drilling service rat-ings. If a pump originally furnished for well servicing isused for drilling service, the oil heat exchanger must be

added, and the 275 HP drilling service ratings must beused.

A WARNINGThe pump must never be operated in

reverse direction, at pressures orspeeds above the maximum valuesshown on the nameplate, or at speedsbelow the minimum value shown inthe back of the manual, without writ-ten permission from Gardner DenverMachinery Marketing.

Failure to observe this warning couldresult in severe pump damage due tooverloading and/or lack of adequatelubrication.

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SECTION 3SERVICE INSTRUCTIONS

FLUID END

CYLINDER -Two different style cylinders are providedfor the PAH pumps to suit the service. Both style cylin-ders are the three-piece block type. Material is heattreated forged alloy steel. The fluid end is provided withremovable bolted-on suction and discharge manifolds.

CYLINDER -Two different style cylinders are providedfor the PAH pumps to suit the service. Both style cylin-ders are the three-piece block type. Material is heattreated forged alloy steel. The fluid end is provided withremovable bolted-on suction and discharge manifolds.

Cylinder is secured to the frame by high tensile strengthconnecting studs. It is important that nuts on thesestuds be checked occasionally for tightness. A loosenut will cause a stud to break under pulsating load. Seeproper tightening torque on page 28.

Cylinder is secured to the frame by high tensile strengthconnecting studs. It is important that nuts on thesestuds be checked occasionally for tightness. A loosenut will cause a stud to break under pulsating load. Seeproper tightening torque on page 28.

The connecting studs extend through the stuffing boxor liner clamp flanges to clamp the stuffing boxes or lin-ers tightly against the face of the cylinder.

The connecting studs extend through the stuffing boxor liner clamp flanges to clamp the stuffing boxes or lin-ers tightly against the face of the cylinder.

FIGURE 2 - BLOCK-TYPE FLUID CYLINDERFOR WATER FLOOD SERVICE

VALVES- In order to keep the pump in its best operat-ing condition, it is necessary to examine the suctionand discharge valves occasionally to see that exces-

sive wear or cutting by the slush or mud has not im-paired their efficiency. Any worn or damaged partsshould be replaced.

This is especially true with regard to the inserts. Stan-dard inserts are made of urethane and are the part ofthe valve which should be changed most frequently.They are less expensive than the valves and seats, andif inserts are renewed as soon as they begin to fail, themore expensive steel parts will last much longer. Rou-tine inspection of valves every two or three days is rec-ommended on drilling and well servicing units.

To remove Water Flood Service Valves, remove thedischarge valve cover stud nuts and valve covers. Re-

move discharge valve cage, spring and valve and pullthe seat from the taper bore with a puller. Repeat thissame procedure for the suction valves. The dischargevalves are larger than the suction valves to permitinstalling and removing suction valves through the dis-charge valve deck in the cylinder.

To remove Drilling and Well Service Valves, removesuction and discharge cover locks and valve coversand the suction valve guide retainer and guide and liftvalve and spring from seat. The seat may be pulledfrom the tapered bore with a puller.

DANGER

If a seat puller powered by a hydraulicjack is used, be certain to chain or tiethe jack down as it will jump violentlywhen valve seat lets go.

If it becomes necessary to resort tothe use of heat or cutting torch to re-move a valve seat, the services of aman experienced in this operation are

necessary.

Before putting new seats in the pump, the tapered borein the valve seat deck must be thoroughly cleaned ofmud or slush with a wire brush. Wire brush should beused around the bore rather than up and down. Wipethe bore clean and do not use oil or grease. The boreunit must be cleaned and dry or seat may not seat prop-erly.

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Place the new seat in the bore. Use an old valve or ablock of hard wood and drive with a sledge to a snuginitial fit. The pressure load on the valve in operation willdrive the seat home.

A ARNINGNever reuse an old seat once it hasbeen removed from a cylinder, as itmay not fit solidly in the valve deck.

Do not put a used valve assembly on a new seat unlessit is in practically new condition. Be sure to replace adoubtful insert to protect seal and bumper.

Replace the upper valve guide if worn (drilling and wellservice units only). Replace the valve spring if it is worn,corroded, distorted or below normal tension. Valves are

provided with stainless steel springs for maximum op-erating life. A broken spring will cause rapid wear ofvalve guides (where used) and should be replaced - Itwill also cause wear on suction valve guide mountinglugs inside the cylinder.

It requires experience and judgement to determine ifvalve parts should be replaced or not. Valves arecheaper than down time.

When installing valves put the gasket carefully in placein the valve chamber and install cover plate. Be certaingasket is not twisted or extruded. On drilling and wellservice units, tighten valve cover lock securely by using

a bar and hammer . On water flood units, tighten eachvalve cover stud nut to the proper torque to preloadstuds to 400 foot-pounds (55 kg-m) (542 N-m). Tight-en cage valve cage to seat 4 to 6 turns to a torque of120 foot-pounds (16.6 kg-m) (163 N-m) for suctionand 140 foot-pounds (19.4 kg-m) (190 N-m) for dis-charge.

The life of the valves will be lengthened if the mud tanksare kept clean. Foreign objects can be caught underthe valves, thereby holding them open and causing rap-id cutting of the seats and valves.

PLUNGER - Water Flood and Well Servicing Units- To remove a plunger, remove coupling bolt and cou-pling which holds the plunger to the push rod. Turn thepump over until the plunger is in the stuffing box as faras it will go. Continue to turn pum p till push rod isbacked away from plunger as far as it will go. Removestuffing box with plunger and packing in the box as acomplete unit. Pull plunger out of packing. The packingcan be installed in THEferred method is toplunger and push

gland as much as possible. Keep gland tight to preventmovement of packing.

A WARNINGAfter removing the plunger to cross-

head extension coupling, do not usea screwdriver or cold chisel to sepa-rate the extension and plungerflanges, as burrs may be formedwhich could cause misalignment onreassembly. Instead, rotate the ec-centric slightly.

If the parts do not separate, carefullyslip a pipe wrench around the plungerneck and use a pulling and rotatingmotion to separate the plunger fromthe extension rod. Use caution toavoid damaging the plunger wear sur-face.

To replace the assembly in pump, reverse above pro-cedure.

Pumps are equipped with plungers made of materialsas required for the service. Hardened steel and colmo-noy plungers are available for the drilling and well serv-icing units. Colmonoy plungers only are available forwater flood pumps.

Tighten frame to cylinder and stuffing box studs to prop-er torque of 500 foot-pounds (69 kg-m) (678 N-m).

PLUNGER STUFFING BOX PACKING - Plungerstuffing boxes are packed with non-adjustable pack-inG.

DANGER

Regardless of the packing used, thegland must be engaged by at least

three (3) threads to hold the pump dis-charge pressure. An improperly tight-ened gland could cause personal in-jury, death, and/or equipment dam-age. This can occur either through di-rect contact with the pressurized flowor by contact with objects the fluidstream propels.

box over the plunger, but the pre-install the packing, then grease thethrough the packing. Tighten the I I

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Always install a complete set when renewing packing.Clean stuffing box thoroughly before installing newpacking. Install junk ring in bottom of stuffing box. Oileach ring thoroughly and install one at a time, begin-ning with bottom adaptor ring. Make sure the lips of thepacking face the pressure. Tighten gland bolt as muchas possible.

Be sure that the glands do not back off while the pumpis operating. Lock in place with lock pins.

DANGER

Do not attempt to adjust packingwhile the pump is in operation toavoid personal injury or death frommoving parts.

Keep packing lubricated at regular intervals by addingmultipurpose grease NLGI Grade No. 2 at the greasefittings located on the top of the stuffing boxes. A forcefeed lubricator is recommended.

LUBRICATOR -A force-feed lubricator is available asoptional equipment to supply oil to the three stuffingboxes. Lubricator is mounted on a bracket over theframe and is driven by linkage connected to a cross-head extension. Oil is delivered to the tapped openingin each stuffing box through copper tubing. Lubricatoris equipped with a check valve at each outlet connec-tion.

Use rock drill oil for normal conditions and steam cylin-der oil for high temperature fluids. Select an oil with theproper pour point for the ambient temperature. Someacceptable oils are listed in the chart on page 26.

Initially set the lubricator to deliver eight (8) to ten (10)drops of oil per minute to each stuffing box. More flowmay be required for large plungers and/or high speeds,pressures or pumped fluid temperatures. Less flowmay be needed for small plungers and/or low speedsor pressures. Flow can be controlled by backing off thejamb nut that locks each plunger body in position on thelubricator and rotating the plunger body. Rotate the

plunger clockwise to increase flow and counter clock-wise to decrease flow. Lock the jamb nuts down againafter making an adjustment. Increase the flow if thepacking starts to heat up.

PISTON LINERS AND LINER CLAMPS-When linersare reinstalled or replaced, it is advisable to check cylin-der to frame stud nuts and tighten if necessary. Referto page 28 for proper tightening torques.

Nuts holding liner clamps in place should not be over-tightened as distortion of the liner clamp and liner bore

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may result. Recommended tightening torque is shownin table on page 28.

Change the size of the pistons and liners as volumeand/or pressure requirements change.

Liners are replaced by removing the liner clamps. Theyshould be cleaned and oiled after removal to protect

against rusting during storage, so they can be usedagain if they are in usable condition.

Pump liners are to be clean both inside and out wheninstalled. Also clean the liner clamp bore and lightly oilall surfaces.

Use new gaskets when installing liners and be sure toclean all surfaces against which the gaskets fit. Linersor fluid cylinders may be cut by leaking gaskets. If pis-tons are properly maintained there will be little or no cut-ting of the liners.

PISTONS - The piston, with piston rods, can be re-moved or installed through the suction valve openingafter the upper valve guide is removed by turning it 90.The valve spring must also be removed.

It is recommended that a piston and rod assembly bekept ready for replacement. This is a practical time sav-er.

PISTON ROD - Piston rods are manufactured of highcarbon steel. They are electrolytically plated to protect

against corrosion. They are provided with a knurledsection so rod can be held while tightening piston nut.It is important that piston rod nut be tightened to recom-mended torque shown on page 28.

Piston rod to piston fit is straight. The piston fits againstthe flange on the piston rod with an 0 ring gasket toprevent leakage. Removal of the piston is a simple op-eration since it is not driven on a taper. Keep piston rodto push rod clamps tight at all times to prevent damageto their flanges and pilots. DO NOT use a screwdriveror cold chisel to separate the flanges. Turn the pumpslightly or use a puller screwed onto piston rod threads

where they extend beyond piston nut.

PISTON WASHING SYSTEM - The piston washingsystem is vital to the satisfactory performance and lifeof pistons and liners. The complete system must bekept in good operating condition. Washing fluid shouldbe maintained in good condition and should be re-placed when contaminated to the point where free cir-culation is impaired. This is of utmost importance andshould be impressed upon all operators of the pump.

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Water supply lines should be permanently attached tothe openings provided in the circulating pump suctionlines between the circulating pump and the tank. Wateris then quickly available as a washing fluid or to flushout the lines by operating the proper valves in the pipingsystem.

The piston washing fluid may be varied according toconditions and operators preference. Water makes asuitable washing fluid under most conditions. Good re-sults can be obtained using water with one-half gallon

of soluble oil per tank of water within the closed system.A light oil gives good results under some conditions,and can be used under severe freezing conditions.

The more fluid circulated, the better; however, it shouldbe regulated by a valve in the discharge line of the cen-trifugal circulating pump to prevent splashing and beingblown about by the wind. Besides making things messyand wasting washing fluid, this could result in danger-ous conditions around the pump when using any of theoil based solutions.

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POWER END

Remove hood and crosshead inspection plates for ac-cess to working parts. Before working inside of crank-case, it is necessary to drain the oil. Oil pump mountingand piping connections are below the oil level.

Mark all parts during dismantling so they can be re-turned to their original position during assembly.

JACKSHAFT- It is advisable to remove eccentric andgear assembly before attempting to remove the jack-shaft. Jackshaft bearings will not clear the gears.

RING FOR LOCATINGBALL BEARING ONJACKHAFT

DET. 1 - Two Reqd. - F.R.O.Matl: Fla me Cut 10" Diameter

from 1-1/4 H.R.S. PlateStraighten - Stress Relieve

FIGURE 3 - JACKSHAFT BEARING DETAIL

P

,ACKSHAFT SUPPORT

Remove all sheaves or other drive members from thejackshaft. Support each end of shaft during removal.

Remove bearing retainer from inner end of bearinghousing. Remove bearing end plate from each side ofthe pump. Remove bearing housing from one side andpull jackshaft and bearing assembly through this open-ing. Opposite bearing housing need not be removedfrom the frame.

Jackshaft bearings are of the double spherical typewith end thrust in both directions taken on the righthand bearing. Both bearings are identical.

The safest way to remove the bearings from the jack-shaft is by the careful use of heat. Do not overheat tothe point where bearing is discolored.

When replacing jackshaft bearings it is necessary tomake a split disc to clamp on the shaft and against theinner face of the outer bearing race to hold race squarewith axis of bearing. See detail in FIGURE 3.

The jackshaft bearings should be replaced if any of therollers or races show damage or if they are excessivelyworn. A noisy bearing indicates bearing damage, re-quiring replacement. Check clearances by insertingfeeler gauge between the roller and inner race withbearing assembled on the shaft and in the housing.This check can be made with the bearing assembledout of the pump. See recommended running clear-ances on page 27.

SPLIT DISC - USEINSTALLATION

ONLY)

FIGURE 4 - JACKSHAFT BEARING INSTALLATION

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To mount new bearings, install split disc (FIGURE 3,page 16) on shaft as shown in FIGURE 4, page 16.Heat bearing in oil to about 300F (149 C) and slip iton the shaft against the bearing shoulder and split disc.The shaft can then be reinstalled in the frame, followedby the eccentric assembly.

To reassemble the jackshaft in the pump, it is neces-sary to reverse the procedure of removal. The teeth ofthe pinion can mesh in only one direction, therefore, thejackshaft is not interchangeable end for end in thepump unless the gear and eccentric assembly is alsoreversed. Reversal of the complete gear set is permis-sible after gear or pinion teeth become badly worn.When gear set is reversed it is necessary to install anew oil pump drive pinion to match the opposite spiralmain gear.

Recomm ended direction of rotation of the pump pro-vides that the outer ends of gear and pinion teeth lead.This means that when viewing from the hood opening,the outer ends of the gear teeth point upward toward

the jackshaft and the outer ends of the pinion teethpoint toward the gear. Gears may be reversed, but thedirection of rotation of the WELL SERVICING PUMPMUST NOT BE REVERSED. Inner ends of teeth willlead after gear set has been reversed.

After the jackshaft is in place with the pinion in meshwith the gear, install the bearing housings. The housingis to be started on the bearing and in the bore of theframe and lightly driven in. Be careful to keep dirt fromthe bearings during assembly. Be sure the gasket is onthe housing. Long threaded studs may be used to pullthe housing into the frame bore. It is well to work bothends at the same time after they have been well startedover the bearing outer race. This will minimize endthrust on the gear teeth. Permanently bolt jackshaftbearing housings and remove the split discs used forpositioning bearings during assembly. When discs areremoved, install the bearing inner retainer, with capscrews and locking wire, on the right hand side of thepump only.

Install the bearing end plate on the right hand side. Pullthe end plate up snug against the bearing with mount-ing screws. Fit shims into the gap between the endplate and housing, then add .010 to .015 more to theshim stack. This .010 to .015" extra shims providesproper running clearance. Remove the end plate,install the shim stack, install the end plate and tightenscrews securely.

Install the left hand bearing end plate. Pull the end plateup snug against the bearing with mounting screws. Fitthe shims into the gap between the end plate and hous-ing. Remove the end plate, install the shim stack,install the end plate and tighten screws securely.

The outer grease seals are to be placed in the bearingend plates after they are bolted to the bearing housings

and frame. Coat inside of the oil seals liberally withbearing grease. Each outer seal is to be installed withgarter spring to inside, toward bearing. Seal bears ona replaceable wear sleeve shrunk onto shaft to preventwear under the seal.

CONNECTING RODS -The connecting rods are splitand bolted together on shims used principally to absorbnormal factory manufacturing tolerances. If the eccen-tric assembly is to be removed from the frame, the con-necting rods need not be unbolted. In this case thecrosshead pins must be removed. Eccentric and rodassembly will lift out of the frame freely if left hand ec-centric is positioned directly above the shaft.

Whether or not the connecting rods need be removeddepends upon the nature of work being done on thePump.

Connecting rod caps can be removed in case it is de-sired to remove eccentric assembly only in order to re-place main bearings.

The connecting rods are provided with high lead bronzeliners which bear against the eccentric. The liners areprecision made in identical halves and are secured byclamps held to the connecting rod and cap by capscrews. They can be replaced by removing connectingrod caps, but without removing connecting rod bodyfrom the pump.

The shims between connecting rods and their caps canbe used to adjust liner to eccentric running clearanceto a limited degree. In no instance should an adjust-ment exceeding .006 inches (.152 mm) be attemptedby this means. The condemnable limit for this bearingis so high that replacement of the liners is preferable to

the limited adjustment the shims provide.The bore in the liner is not round, but a compound boredesigned to give maximum bearing surface. Field shopreboring of the liners is not recommended for this rea-son.

Connecting rods are drilled to conduct oil under pres-sure to crosshead pin bushings. These bushings arebored to size after they are factory assembled . Wheninstalling repair bushings it may be necessary to honeto proper running fit over the crosshead pins as shownin table on page 27.

ECCENTRIC AND BEARING ASSEMBLY

IMPORTANT: Be sure to remove oil pump drive pinionwhen removing or replacing eccentric and gear assem-bly to avoid bending oil pump shaft when gear ismoved.

Eccentric runs on two double row spherical roings supported by the station ary main shaft.

ller bear-

To remove the eccentric and gear assembly, removehood, and remove the connecting rod caps. Be surecaps are marked so they can be replaced in their origi-nal position. Keep shims in their original position.

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Remove clamps that hold the main, or eccentric shaftto frame. Be sure clamps are identified so they can bereturned to their original position.

Lift the eccentric assembly from the frame. Remove themain bearing retainer plates from each end of the ec-centric and drive the shaft out with a block of wood anda hammer.

Bearings are slip fit on the shaft and a light press fit inthe bearing bore in the eccentric.

Bearings are to be replaced if worn excessively or ifdamaged. A damaged bearing will be noisy. Do not re-move protective grease in new bearings. It will notcontaminate the crankcase oil.

When new bearings are to be installed, be sure to re-place the rubber quad ring seals inside the bronze sealretainers pressed into the eccentric bore just inside theeccentric bearings. These seals bear on the shaft andprevent loss of oil pressure to the eccentric cams andconnecting rods.

MAIN GEARS -After long wear the main gears can bereversed by changing eccentric and gear assemblyend for end, or by exchanging the gears on the eccen-tric. In either case it is also necessary to change thejackshaft end for end. When gear set is reversed it isnecessary to install a new oil pump drive pinion tomatch the opposite spiral main gear. It is not possibleto move the oil pump to opposite side of the frame inthis pump.

In a new pump the gears are mounted so the outer endsof the teeth lead. If gears are reversed, the outer endsof the teeth will follow.

Gears are located on the eccentric flange by means ofone cap screw which is larger than the rest. It shouldbe inserted first, and all cap screws tightened evenlyand wired in pairs.

Lower the eccentric assembly, with main shaftinstalled, into the frame after jackshaft has beeninstalled. Secure shaft to frame with saddles. Seetorque table on page 28 for proper tightening of thesaddle stud nuts.

Reassemble connecting rod caps in original position.Be sure original shims are in place. See table on page28 for tightening of the connecting rod bolt nuts.

Check crankcase for tools or other parts and fill withnew oil before replacing hood.

PUSH RODS - Push rods can be removed from thecrossheads by working through handhole plates in thesides of the frame and also through the oil stop open-ings after the oil stop head assemblies have been re-moved.

Be careful not to damage the highly polished surface onwhich oil seals bear.

3-l-605

CAUTION

Extension rods are plated and shouldbe protected when the pump is re-painted. Paint on the extension rodswill damage oil stop head seals whenthe pump is operated.

Push rods are chrome plated and should be protectedwhen the pump is painted. Paint will damage oil stophead seals.

CROSSHEADS AND PINS - Crossheads are of one-piece construction without removable shoes. Theybear on slides bored in the frame.

Crossheads are equipped with straight full-floatingpins secured each end by spring retainers in groovesnear the ends.

The retainer rings can be reached from the main hoodopenings or through the crosshead inspection plateson the sides of the frame. It will be necessary to turn thepump over to locate each crosshead for accessibilitywhile removing the crosshead pins.

Crossheads may be removed by removing oil stopheads, push rods and crosshead pins. Slide the cross-heads through the oil stop bores in the frame and liftthem clear. Be careful to protect the shoe surfaces fromdamage. Also protect the lower slide in the frame byplacing a wooden block beneath the small end of theconnecting rod.

It is necessary to remove one outer crosshead beforethe center one can be reached for removal. Contact thefactory for availability of oversize crossheads.

OIL STOP HEADS-Oil stop heads keep crankcase oilwithin the frame. They also keep mud and liner washingwater from entering the crankcase.

.0ILsea

stop packing consists of two identical urethaneIs mounted in adaptors. They are not adjustable.

The inner seal lip is pointed inward toward the crank-

case to strip oil from the push rod. The outer seal lippoints outward toward the liner to strip mud and/or wa-ter from the push rod. Be certain seals are properly lo-cated.

The seal adaptors, with seals in them, can be slippedoff and on the push rods by removing the clamp holdingpiston rods against the push rods and separating thetwo flanges. DO NOT use a screwdriver or drift to sepa-rate the push rod and piston rod flanges. Turn the pumpslightly.

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A WARNINGWhen installing oil stop head sealrings, care must be taken not to dam-age sealing lips. Damaged lips couldlead to excessive oil leakage and/orcrankcase contamination and dam-age.

It is essential that the oil stop head seals be replacedat the first indication of leakage. Oil leakage will be indi-cated by oil collecting on top of the liner washing waterin the reservoir. If rig water is used for washing, and runto a waste area, it is difficult to check by the abovemethod.

If oil leakage is serious it will show up in a lower oil levelin the crankcase. In this case oil must be added to thecrankcase as required, until a new oil stop seals can beinstalled.

Leakage of mud and water into the crankcase will beindicated by a milky appearance of the crankcase oil.If excessive, the mud can be detected by reachingthrough the oil with the hand, or by draining out a smallquantity of oil.

Mud will also be seen below the oil stop heads on theinside of the crankcase through the crosshead inspec-tion plate openings.

When mud is found in the crankcase, the oil should bechanged. Drain and clean out the crankcase beforeputting in the new oil. Replace the mud scraper sealsin the oil stop heads before running the pump.

A WARNINGWhen mud or other foreign material isfound in the crankcase, the oil mustbe changed before operating pump toavoid damage to moving parts.

We recommend the oil stop head seals be changed ev-ery six months of operation, even though leakage is notevident.

Rubber baffles are provided as standard equipment toreduce the amount of abrasive fluid entering the powerend and must be installed on all three extension rods.

A WARNINGFailure to properly reinstall and main-tain baffles voids the warranty as theyare designed to help prevent mud andother contaminants from enteringand damaging the crankcase.

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SECTION 4TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Pump Overloads Driver. 1.

Fluid Not Delivered.

Low Discharge Pressure.

Low Suction Pressure.

2.

3 .

4. Improper bypass conditions.

1.

2.

3 .

4.

1.

2. Valve propped open.

3 . Pump cavitating.

Excessive pump speed

and/or discharge pressu

Blockage or closedvalve in discharge line.

Incorrect plunger size.

re.

Pump not primed.

Air or vaporsuction line.

pocket in

Clogged suction line.

Suction and/or dischargevalves propped open.

Worn or fluid cut valveassembly.

4. Fluid leakage.

5 . Erroneous g auge reading.

1. Low head (NPSH

2. lnsufficient chargINGcapacity.

.

Pump

3 . Retarded fluid flow.

4. Erroneous gauge reading.

Cavitation, Fluid Knock or Hamm er. 1. Improper suction systemlayout.

2. Low suction pressure.

3 . Suction stabilizer andpulsation dampener not used.

4. Defective stabilizer ordampener.

1.

2.

3 .

4.

1.

2.

3 .

4.

1.

2.

3 .

4.

5 .

1.

2.

3 .

4.

1.

2.

3 .

4.

Reduce pump speed and/or

pressure.

Clean or open valve.

Install the correctplunger.

See recommended systemlayout, and correct error.

Prime pump.

Remove pocket from line.

Clean out line.

Remove prop.

Replace valve assembly.

Remove prop.

See Cavitation, Fluid Knockor Hammer problem.

Replace plungers/packingand/or fluid end seals.

Recalibrate or replacegauGE(S)

Raise fluid supply level.Install charging pump.

Increase charging pumpspeed or size.

Remove restrictions fromsuction line.

Recalibrate or replacegauGE(S)

See recommended systemlayout in manual.

See Low Suction Pressureproblem.

Install suction stabilizerand pulsation dampener.

Repair and recharge orreplace.

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26/35


Cavitation, Fluid Knock or Hamm er(continued).

5 . High fluid temperature or 5 .viscosity.

6 . High fluid vapor pressure. 6 .

7. High acceleration head. 7.

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

9 . Air/Gas in pumped fluid. 9 .

10. Air entering suction line.

11. Air entering charging pump.

10 .

11.

12. Air entering or charge gas 12.escaping from suction stabilizer.

13. Multiple pumps operating inphase.

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

2. Pump cavitating.

High Crankcase Oil Temperature. 1. High ambient temperature.

2. Improper type/grade oil used.

3 . Pump overloaded.

4. Improper clearance in main orrod bearings, crossheads orbushings.

Knock In Power End.

13 .

1.

2.

1.

2.

3 .

4.

1. Improper main bearing clearance. 1.

2. Incorrect pump rotation. 2.

3 . Loose plunger coupling. 3 .

4. Loose extension rod. 4.

5 . Loose connecting rod cap. 5 .

6 . Loose bearing housings/covers. 6.

7. Worn crosshead pin. 7.

Redu ce pump speed perchart in manual.

Increase NPSH.

Increase supply line size.Decrease supply line length.

Use more flexiblespring.

Remove inner spring fromtwo spring valve.

Allow more settling timein supply tank.

Reduce pump speed.

Repair suction line.

Tighten or replace shaftpacking or seal.

Repair and rechargestabilizer.

Use a suction stabilizeron each pump. Separatelines may also be needed.

Install supports or hangers.


Use an oil heat exchangerwith a circulating pump.

Use recommended oil.

Reduce ppressure.

ump speed a nd/or

Check and adjust clearance.Replace parts as required.

Check clearances.

Reverse rotation.

Check and tighten. Replace

if damaged.Check and tighten. Replaceif damaged.

Check and tighten. Replaceif damaged.

Check and tighten. Replaceif damaged.

Replace.

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Knock In Power End (continued). 8 . W orn crosshead pin bushing. 8 .

9 .

Replace.

Replace.. Worn connecting rod linerbearing eccentric.

10. Worn crankshaft.

11. Worn crosshead.

12. Worn main bearing.

10 .

11.

12.

13 .

Replace.

Replace.

Replace.

13. Valve noise transmitted topower end.

14. Cavitation noise transmitted to,or causing shock loading in,power end.

See Excessive Valveproblem.

See Cavitation, Fluidor Hammer problem

Noise

Knock4.

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

Replaced seal or valve.. Seal on inserted valvedamaged or missing.

2.

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

Oil Leakage From StopHead.

1. Worn, damaged or corrodedextension rod.

2. Worn oil stop head packing.

3 . Oil level too high incrankcase.

4. Excessive crosshead wear.

5 . Pressure in crankcase.

1. Worn sealing lip.

2. Damaged sealing lip.

3 . O.D. not seated.

4. Shaft rough at seal lip.

5 . Pressure in crankcase.

1. Short plunger/packing life.

2. Worn packing rings/metal.

3 . Gasket leaking at fluidcylinder.

1. Replace extension rod.

2.

3 .

Replace packing.

Reduce oil level.

4.

5 .

Replace crosshead.

Clean or replace air breather.

Oil Seal Leakage. Replace seal.

Replace seal.

Clean and polish bore ofoil seal housing.

Clean and polish shaft orreplace wear sleeve.

Clean or replace air breather.

1.

2.

3 .

4.

5 .

Stuffing Box Leakage. See Short Plunger/PackingLife problem.

Replace packing rings/metal.

Check gasket, stuffing boxgroove and cylinder sealingsurface.

1.

2.

3 .

3-I-605 Page22


28/35


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

2. Worn oil stop head packing. 2.

3 . Stuffing box leakage . 3 .

4. Extension rod baffles damaged/ 4.

Short Valve Life.

Short Plunger/Packing Life. 1. Abrasives in pumped fluid.

missing.

1. Abrasives in pumped fluid.

2. Valve not sealing.


4. Corrosion.

2. Excessive plunger/packingfriction.

3 . Metal parts or particleswearing plunger.

4. Wrong plunger/packing forpumping conditions.

5 . Wrong size packing.

1.

2.

3 .

4.

3 .

4.

5.

Replace extension rod.

Replace packing.

See Stuffing Box Leakageproblem.

Install new baffles.

Filter pumped product.Use severe duty valveswith insert.

Broken valve spring -replace.

Worn valve guide - replace.

Worn valve/seat - replace.


Treat pumped fluid.

Use different materialsfor valves/seats.

Install sacrificial anodesin suction manifold.

Consult G-D CustomerService for plunger/packing recommendation.

Filter pumped fluid.Lubricate with rock drill oil.

Do not overtighten adjust-able packing.

Use Gardner Denverplungers.

Check stuffing boxalignment.

Check gland alignment.

Check plunger alignment.

Check packing for foreignparticles.

Replace gland bushing.

Replace lantern ring.

Consult G-D CustomerService.

Install correct size packing.

3-I-605 Page23


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Short Plunger/Packing Life 6 . Improper packing installation.(Continued).

Catastrophic Failures Such AsBroken Shafts, Bent Rods, etc.

7. Excessive crosshead wear.


1. Pump overloaded.

2. Start-up against closeddischarge valve.

3 . Main bearing failure.

4. Plunger striking valve orvalve parts.

5 . Plunger striking cylinder.

6 . Frozen fluid in cylinder.

Stud Failures.

7.

8 .

9 .

1.

2.

3 .

4.

5 .

6 .

Low oil level in sump.

Contaminated oil in sump.

Cavitation shock loading.

Catastrophic failures.

Improper nut torquing.

Stud bending due to unevennut seating.

Corrosive attack by pumpedfluid.

Studs damaged beforeinstallation.

Low strength studs.

6 .

7.

8 .

1.

2.

3 .

4.

5 .

6 .

7.

8 .

9 .

1.

2.

3 .

4.

5 .

6 .

Check installation procedureand install correctly.

Replace crosshead.

See Cavitation, Fluidor Hammer problem.

Reduce pump speedpressure.

Insure valve is openbefore starting.

Repair or replace.

Knock

and/or

Check valve condition andinstallation procedure.

Check plunger for properlength.

Do not start pump whenpumped fluid is belowfreezing temperature.

Check oil level frequently,and add oil as required.

Check oil conditionfrequently.


See Catastrophic Failuresproblem.

Check torque specificationsand torque to correct values.

Check nut seat surface forflatness. Rework or replaceas required.

Treat fluid or use corrosionresistant studs.

Check condition beforeinstallation, and replace ifnecessary.

Use Gardner Denver studs.

3-I-605 Page 24


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API-GL5 AmbientOil Grade Temperature

CrankcaseOperating OilTemperature

Minimum StartupOil Temperature

75w-90 -20 F to 60 F 60 Fto 140 F 20 F(-29 C to 16 C) (16 C to 60 C) (-7 C)

80W-140

80

90

140

100 F to 100 F 90 Fto 180 F 50 F(-12 C to 38 C) (32 C to 82 C) (10 C)

-100 F to 45 F 70 Fto 125 F 30 F(-23 C to 7 C) (21 C to 52 C) (-10 C)

20 F to 80 F 100 Fto 160 F 60 F(-7 C to 27 C) (38 C to 71 C) (16 C)

50 F to 115 F 130 Fto 195 F 80 F(IO C to 46 C) (54 c to 90 C) (27 C)

* An 80 F (27 C) crankcase oil temperature rise over ambient air temperature is typical for the pumps coveredby this manual when operating at or near rated horsepower.

Oil viscosity must not exceed 7000 SSU at start-up and must be between 1500 SSU and 200 SSU while operating,regardless of the oil temperature or grade used. A crankcase heater and/or an oil heat exchanger may be neededto meet these requirements.

Crankcase capacity is 30 gallons (113.6 liters).

A WARNING

Failure to follow these lubrication requirements will void the warranty.

3-l-605 Page 25

8/12/201

MANUAL PJ-8 Operating and Services Manual

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Transcript of MANUAL PJ-8 Operating and Services Manual