gardner denver mud pump service manual pricelist

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RTRIPLEX PLUNGER PUMPMODELTGHOPERATING ANDSERVICE MANUAL316102nd EditionJune, 199731610 Page iMAINTAIN PUMP RELIABILITY AND PERFORMANCE WITHGENUINE GARDNER DENVERPARTS AND SUPPORT SERVICESGardner DenverR and OPIR genuine pump parts aremanufactured to original tolerances and designed foroptimum dependability. Design and material innova-tions are the result of years of experience withhundreds of different pump applications. Reliability inmaterials and quality assurance are incorporated in ourgenuine replacement parts.Your authorized Gardner Denver and OPI distribu-tor offers all the backup youll need. A worldwidenetwork of authorized distributors provides the finestproduct support in the pump industry.Your local authorized distributor maintains a large in-ventory of genuine parts and he is backed up for emer-gency parts by direct access to the Gardner DenverMachinery Inc. Master Distribution Center (MDC) inMemphis, Tennessee.Your authorized distributor can support your GardnerDenver and OPI pump needs with these services:1. Trained parts specialists to assist you in select-ing the correct replacement parts.2. Repair and maintenance kits designed with thenecessary parts to simplify servicing your pump.Authorized distributor service technicians are factorytrained 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: Factory:Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.Master Distribution Center 1800 Gardner Expressway5585 East Shelby Drive Quincy, IL 62301Memphis, TN 38141 Phone: (217) 2225400Phone: (901) 3636100 Fax: (217) 2247814Fax: (901) 3631095INSTRUCTIONS FOR ORDERING REPAIR PARTSWhen ordering parts, specify Pump MODEL and SE-RIAL NUMBER (see nameplate on unit). The SerialNumber is also stamped on top of the cylinder end ofthe frame (cradle area).All orders for Parts should be placed with the near-est authorized distributor.Where NOT specified, quantity of parts required perpump or unit is one (1); where more than one is requiredper unit, quantity is indicated in parenthesis. SPECIFYEXACTLY THE NUMBER OF PARTS REQUIRED.DO NOT ORDER BY SETS OR GROUPS.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-thesis following the part name, i.e. (RH) & (LH), whenappropriate.31610 Page iiFOREWORDGardner DenverR and OPIR 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 daytoday 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.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 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 is used to notify people of installation, operation or maintenance informationwhich is important but not hazardrelated.31610 Page iiiTABLE OF CONTENTSMaintain Pump Reliability and Performance with Genuine Gardner Denverr Partsand Support Services i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for Ordering Repair Parts i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1, Danger Notices 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2, Installation & Operating Instructions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sectional View of TGH Pump With Block Fluid Cylinder 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3, Service Instructions 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4, Trouble Shooting 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggested Periodic Maintenance Schedule Power End 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggested Periodic Maintenance Schedule Fluid End 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger Packing Lubrication Recommendation Chart 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rock Drill Lubricants 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steam Cylinder Oils 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5, Dimensions & Running Clearances 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Torques 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Last Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For Parts List see:PARTS LIST # 3151931610 Page ivINDEXBearing and Eccentric Assembly 17 . . . . . . . . . . . . . . . Connecting Rods 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Covers and Guards, Danger Notice 2 . . . . . . . . . . . . . . Crankcase Oil Requirements 29 . . . . . . . . . . . . . . . . . . Crossheads and Pins 18 . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANGER NOTICES, SECTION 1 1 . . . . . . . . . . . . . . . Danger NoticesCovers and Guards 2 . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Moving and Lifting 2 . . . . . . . . . . . . . . . . Flammable, Hot, Cold or Corrosive Fluid Pumping 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Lug Fasteners 1 . . . . . . . . . . . . . . . . . . . . . High Pressure Liquid Jetting, Blasting and Cleaning 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Pump Systems 3 . . . . . . . . . . . . . . . . . . Valve Seat Pulling 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge Puller 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS & RUNNING CLEARANCES,SECTION 5 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric and Bearing Assembly 17 . . . . . . . . . . . . . . . Equipment Moving and Lifting, Danger Notice 2 . . . . . Extension Rods 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Gear Reducer 19 . . . . . . . . . . . . . . . . . . . . . . . . Figure 1 Sectional View of PAH/TGH Pump with Block Fluid Cylinder 11 . . . . . . . . . . . . . . . . . . . . . . . Figure 2 Sectional View of Fluid Cylinder 12 . . . . . . Figure 4 Jackshaft Bearing Detail 16 . . . . . . . . . . . . . Figure 5 Jackshaft Bearing Installation 16 . . . . . . . . Filter, Oil 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flammable, Hot, Cold or Corrosive Fluid Pumping,Danger Notice 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Reducer, External 19 . . . . . . . . . . . . . . . . . . . . . . . Gears, Main 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Lug Fasteners, Danger Notice 1 . . . . . . . . . . Heat Exchanger 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Liquid Jetting, Blasting and Cleaning,Danger Notice 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Puller, Danger Notice 2 . . . . . . . . . . . . . . . . . Installation 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION AND OPERATING INSTRUC-TIONS, SECTION 2 7 . . . . . . . . . . . . . . . . . . . . . . . . Introduction i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jackshaft 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting and Moving Equipment, Danger Notice 2 . . . . . Long Term Storage 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricator 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Gears 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving and Lifting Equipment, Danger Notice 2 . . . . . Oil Filter 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Stop Heads 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic Maintenance Schedule, Power End 27 . . . . . Periodic Maintenance Schedule, Fluid End 28 . . . . . . Piston Liners and Liner Clamps 14 . . . . . . . . . . . . . . . . Piston Rod 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Washing System 14 . . . . . . . . . . . . . . . . . . . . . . . Pistons 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger Packing, Lubrication Recommendation Chart 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rock Drill Lubricants 30 . . . . . . . . . . . . . . . . . . . . . . . Steam Cylinder Oils 30 . . . . . . . . . . . . . . . . . . . . . . . Plunger Stuffing Box Packing 13 . . . . . . . . . . . . . . . . . . Power End 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Relief Valve 7 . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Pump Systems, Danger Notice 3 . . . . . . Pump, Oil 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Parts, Ordering Instructions i . . . . . . . . . . . . . . Running Clearances, Recommended 31 . . . . . . . . . . . SERVICE INSTRUCTIONS, SECTION 3 12 . . . . . . . . Service Instructions 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . Power End 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slow Speed Operation of WellServicing Pumps 9 . . Starting a New Pump 8 . . . . . . . . . . . . . . . . . . . . . . . . . . Storage, Long Term 10 . . . . . . . . . . . . . . . . . . . . . . . . . . Suction System 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torques, Recommended 32 . . . . . . . . . . . . . . . . . . . . . . TROUBLE SHOOTING, SECTION 4 21 . . . . . . . . . . . . Valve Seat Pulling, Danger Notice 2 . . . . . . . . . . . . . . . Warranty Last Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge Puller, Danger Notice 2 . . . . . . . . . . . . . . . . . . . WellServicing Pumps, Slow Speed Operation 9 . . . . 31610 Page 1SECTION 1DANGER NOTICESRead and understand the following DANGER NO-TICES 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 DenverMachinery 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 pumpsystem 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 maintenancepersonnel to refresh their memories in safe proceduresand practices.Keep in mind that full operator attention and alertnessare 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 FASTENERSOn 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 dueto 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:S 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.S Wear safety shoes and goggles.S Alert other personnel to move away from thearea.S Check to insure they have safe footing.S Fully engage the hammer bar, if one is used, toprevent it from disengaging violently from thecover as a blow is struck.S 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.31610 Page 2S Carefully swing the hammer to avoid strikingthemselves, another person and objects otherthan the targeted lugs or hammer bar.S Avoid swinging the hammer above shoulderheight.VALVE SEAT PULLINGThe 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 PullerS Wear safety shoes and goggles.S Chain or tie the jack down as it will jump violentlywhen the valve seat disengages from the valvedeck.S Check to insure the pressure applied by the hy-draulic pump does not exceed the hydraulicram maximum pressure rating.Wedge PullerS Grind off any mushroomed material from thewedge before use.S Follow the danger notices listed above in thehammer lug section, but substitute the termwedge for hammer lug and hammer bar.COVERS AND GUARDSAll 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 movingparts 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.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 LIFTINGHeavy 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.Failure to follow safe and properpump, 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.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.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.31610 Page 3For 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 SYSTEMSFluids 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.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.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 clogged with solid material carried in the fluid,which could prevent proper relief valve operation.Never place a shutoff 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:S The pressure relief valve is in good operatingcondition and has been set to the proper reliefpressure.S Any pipe line used to direct pressurized reliefflow to another location, such as a collectingtank, is not blocked.S 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.31610 Page 4Worn 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 hexand 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 allcomponents 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.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 from turning and make certain thatall pump drive motor or engine start switches or startercontrols 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 FLUIDPUMPINGExtreme 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, suction31610 Page 5system 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 shutoff. 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 shutoff if an air inlet shutoff 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.HIGH PRESSURE LIQUID JETTING, BLASTINGAND CLEANINGExtreme 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, whichcould 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 coulddangerously 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 shutoff equipment isoperating properly before every use and never circum-31610 Page 6vent the automatic shutoff 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 automaticshutoff, pressure and control equipment should betreated with care. Protect them from damage bypeople, objects 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.31610 Page 7SECTION 2INSTALLATION & OPERATING INSTRUCTIONSAlways 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, straightsuction 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, with a 10 foot (3 meter) suctionhead minimum.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 airtight.Both air pockets and air leaking into the line will reducepump volumetric efficiency and produce shock loadinginside the pump. Any bends in the suction line shouldbe long radius sweeps. All piping must be supportedindependently of the pump to insure that no strain is im-posed on the pump by misalignment, vibration or im-properly fitted pipe. Any suction line shutoff valve(s)must be full opening to avoid choking the pump.If 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.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.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.31610 Page 8STARTING 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 andscrews 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 or pack-ing when starting, the pump should be started slowlyand should be operated for a short period with practical-ly no discharge pressure. Use the recirculation line(discharge flow bypass back to suction inlet), by open-ing the recirculation line valve to perform this operation.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.Pumps are shipped from the factorywithout oil in the crankcase.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.The pump must be primed at startupto prevent damage to packing andplungers.The oil level on the pump should be checked with thepump running. The running level on the pump shouldbe between the middle and top of the sight glass in theoil level indicator, located on the side of the pumpframe. Add oil through the threaded opening where thebreather is mounted to the hood. The pump may thenbe brought up to working speed and pressure. Checkfor overheating and listen for abnormal noise. Inspectall joints in the suction line to be sure there are not airor fluid leaks. Check for excessive vibration caused byimproper suction conditions. Be sure the stuffing boxpackings are properly lubricated per the directions giv-en in the packing lubricator section. If equipped withpiston and liner, be sure liner/piston wash system is op-erating properly.LUBRICATION The eccentric, crossheads, connect-ing rods and main bearings are lubricated by oil in thecrankcase.Use only extreme pressure, API GL5gear 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 GL5 oil must have antiwear, antifoaming, 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 startup 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 at 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 startup 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,31610 Page 9if care is taken to stay within the listed temperatureranges. Straight weight oils are also ideal in pumpsused 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 severalweeks, turn the pump over a few times to coat workingparts before draining the oil from the crankcase. Thiswill protect the power end parts against damage byrust. For long term storage, see page 10.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.The oil should be checked for con-tamination whenever pumped fluidsprays or splashes against an oil stophead. This is especially critical whenthe 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 theplugs 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 GL5oils containing antifoaming additives are used. Oilfoaming can cause pump 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 geardriven rotarytype pump which provides filtered oil under pressure toconnecting 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 WellServicing Pumps When the pump is operated below 100 RPM, specialauxiliary oil pump and piping must be installed to main-tain adequate lubrication. Oil pressure of 25 PSI mini-mum must be maintained at all times. The auxiliary oilpump should have a capacity of 15 gallons per minuteor greater.Do not operate the Well ServicingPump below 34 RPM.Do not operate the 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.31610 Page 10The filter element should be replaced each time thecrankcase oil is changed or every 1000 hours.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 the pump. The heatexchanger maintains crankcase oil temperature at160_ F (71_ C) maximum.The pump must never be operated inreverse 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.LONG TERM STORAGE The following procedureshould be followed for long term storage of the unit.1. Drain and thoroughly clean the inside of the powerend crankcase.2. Spray a rust inhibiting oil on all bearings, ma-chined surfaces and the inside surface of the pow-er end. Add a vapor phase inhibitor oil to thecrankcase. (Example shell VSI oil follow themanufacturers instructions.) The power endmust then be tightly sealed from outside air.3. Clean gear oil should be induced into the oil circu-lating pump, filter, heat exchanger and piping.4. Remove valves, seats, pistons and liners, orplungers and packing from the fluid end. Theseparts should be thoroughly cleaned and dried.Thoroughly clean fluid cylinder bores. Coat all cyl-inder bores, valve covers, valve cover locks andreusable expendable parts with a rust preventa-tive or grease. Box and cover the expendableparts and cover the fluid end openings with piecesof wood to prevent animal nesting.5. If exterior paint has deteriorated, the pump shouldbe repainted.6. Flush all water, sand and debris from the piston liner wash pump, tank, hoses and spray nozzles.Spray all components with a rust inhibiting oil andfill the wash pump housing with oil.3

610 Page 11FIGURE 1 SECTIONAL VIEW OF PAH/TGH PUMP WITH BLOCK FLUID CYLINDERD7625731610 Page 12SECTION 3SERVICE INSTRUCTIONSFLUID ENDCYLINDER Fluid cylinders are the threepiece blocktype. Material is heat treated forged alloy steel. Thefluid end is provided with removable boltedon suctionand discharge manifolds.Each cylinder is secured to the frame by high tensilestrength connecting studs. It is important that nuts onthese studs be checked occasionally for tightness. Aloose nut will cause a stud to break under pulsatingload. See proper tightening torque on page 32.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 SECTIONAL VIEW OF FLUID CYLINDERVALVES 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 valves, remove suction and discharge coverlocks and valve covers and the suction valve guide re-tainer and guide and lift each valve and spring fromseat. The seat may be pulled from the tapered bore witha puller.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 arenecessary.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.31610 Page 13Place the new seat in the bore. Use a block of hardwood and drive with a sledge hammer to a snug initialfit. The pressure load on the valve in operation will drivethe seat home.Never 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. Replace thevalve spring if it is worn, corroded, distorted or belownormal tension. Valves are provided with stainlesssteel springs for maximum operating life. A brokenspring will cause rapid wear of valve guides and shouldbe replaced. It will also cause wear on suction valveguide mounting lugs 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 usinga bar and hammer.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 To remove a plunger, remove couplingbolt and coupling which holds the plunger to the pushrod. Turn the pump over until the plunger is in the stuff-ing box as far as it will go. Continue to turn pump tillpush rod is backed away from plunger as far as it willgo. Remove stuffing box with plunger and packing inthe box as a complete unit. Pull plunger out of packing.The packing can be installed in the box over the plung-er, but the preferred method is to install the packing,then grease the plunger and push through the packing.Tighten the gland as much as possible. Keep glandtight to prevent movement of packing.After 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.Standard equipment plungers are colmonoy coated.Other materials can also be supplied, if required.Tighten the frame to cylinder and stuffing box studs tothe proper torque of 500 footpounds (69 kgm) (678NSm).PLUNGER STUFFING BOX PACKING Plungerstuffing boxes are packed with 838 style packing fordrilling service and 1067 style for well service.Regardless of the packing used, thegland must be engaged by at leastthree (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.31610 Page 14Always 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.Do not attempt to adjust packingwhile the pump is in operation toavoid personal injury or death frommoving parts.LUBRICATOR Packing must be lubricated. A forcefeed lubricator is available as optional equipment tosupply oil to the three stuffing boxes. Lubricator ismounted on a bracket over the frame and is driven bylinkage connected to a crosshead extension. Oil is de-livered to the tapped opening in each stuffing boxthrough copper tubing. Lubricator is equipped with acheck valve at each outlet connection.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 30.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 theplunger 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 32 for proper tightening torques.Nuts holding liner clamps in place should not be over-tightened as distortion of the liner clamp and liner boremay result. Recommended tightening torque is shownin table on page 32.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 protectagainst 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 protectagainst 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 32.Piston rod to piston fit is straight. The piston fits againstthe flange on the piston rod with an O 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 threadswhere 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.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.31610 Page 15The 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 onehalf gallonof 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 slipping conditions around the pump when usingany of the oil based solutions.31610 Page 16SERVICE INSTRUCTIONSPOWER ENDRemove 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.A938FIGURE 3 JACKSHAFT BEARING DETAILRING FOR LOCATINGBALL BEARING ONJACKHAFTDET. 1 Two Reqd. F.R.O.Matl: Flame Cut 10 Diameter from11/4 H.R.S. PlateStraighten Stress Relieve7366364311613238RR1181182DET 2 Four Reqd. 16 x 2 SOC. Head Cap Screen38Letter O Drill 2 DeepDrill to Split25643816 TAP 118DeepTwo HolesView at R R5.537 Dia.(Flame Cut to 4 Dia.)12121212121212ARemove 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