gardner denver mud pump service manual free sample

MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Gardner DenverR and OPIR genuine pump parts are manufactured to design tolerances and developed for optimum dependability. Design and material innovations are the result of years of experience with hundreds of different pump applications. Reliability in materials and quality assurance are incorporated in our genuine replacement parts. Your authorized Gardner Denver and OPI distributor offers all the backup youll need. A worldwide network of authorized distributors provides the finest product support in the pump industry. Your local authorized distributor maintains a large inventory of genuine parts and he is backed up for emergency parts by direct access to the Gardner Denver Master Distribution Center (MDC) in Memphis, Tennessee. Your authorized distributor can support your Gardner Denver and OPI pump needs with these services: 1. 2. Trained parts specialists to assist you in selecting the correct replacement parts. Repair and maintenance kits designed with the necessary parts to simplify servicing your pump.

Authorized distributor service technicians are factory-trained and skilled in pump maintenance and repair. They are ready to respond and assist you by providing fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Gardner Denver Master Distribution Center 5585 East Shelby Drive Memphis, TN 38141 Phone: (901) 542-6100 Fax: (901) 542-6159 Factory: Gardner Denver 1800 Gardner Expressway Quincy, IL 62301 Phone: (217) 222-5400 Fax: (217) 224-7814

INSTRUCTIONS FOR ORDERING REPAIR PARTS When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit). The Serial Number is also stamped on top of the cylinder end of the frame (cradle area). All orders for Parts should be placed with the nearest authorized distributor. Where NOT specified, quantity of parts required per pump or unit is one (1); where more than one is required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED. DO NOT ORDER BY SETS OR GROUPS. To determine the Right Hand and Left Hand side of a pump, stand at the power end and look toward the fluid end. Right Hand and Left Hand are indicated in parenthesis following the part name, i.e. (RH) & (LH), when appropriate.

FOREWORD Gardner DenverR and OPIR pumps are the result of advanced engineering and skilled manufacturing. To be assured of 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 dayto-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and minimum downtime.

TABLE OF CONTENTS Maintain Pump Reliability and Performance ..........................................................................................................i Instructions For Ordering Repair Parts...................................................................................................................i Foreword................................................................................................................................................................ii Index .....................................................................................................................................................................iv SECTION 1, Danger Notices................................................................................................................................ 1 SECTION 2, Installation & Operating Instructions................................................................................................ 7 SECTION 3, Routine Maintenance & Service Instructions................................................................................. 16 SECTION 4, Dimensions & Running Clearances............................................................................................... 28

Maintain Pump Reliability And Performance ...............i Ordering Repair Parts..................................................i Foreword.....................................................................ii SECTION 1................................................................ 1 Hammer Lug Fasteners............................................. 1 Valve Seat Pulling...................................................... 2 Hydraulic Puller.......................................................... 2 Wedge Puller ............................................................. 2 Covers And Guards ................................................... 2 Equipment Moving And Lifting................................... 2 Pressurized Pump Systems ...................................... 3 Flammable, Hot, Cold Or Corrosive Fluidpumping.... 4 High Pressure Liquid Jetting, Blasting And Cleaning 5 SECTION 2................................................................ 7 Start-Up ..................................................................... 7 Location ..................................................................... 7 Suction Line ............................................................... 8 Relief Valves.............................................................. 8 Surge Chamber ......................................................... 8 Starting A New Pump ................................................ 8 Lubrication ................................................................. 9 Oil Filter ................................................................... 10 Heat Exchanger ....................................................... 10 Direction Of Rotation ............................................... 10 Crosshead Drains .................................................... 11 Operation ................................................................. 11

Maintenance Schedule.............................................11 SECTION 3...............................................................16 Jackshaft ..................................................................16 Lube Oil Pump..........................................................18 Connecting Rods ......................................................18 Eccentric And Gear AssemblyError! Bookmark not defined. Eccentric Cam Bearings...........................................20 Assembly Of Eccentric And Gear Assembly In Frame ..................................................................................21 Main Bearings...........................................................21 Crosshead Pins ........................................................24 Push Rods ................................................................24 Crossheads ..............................................................25 Crosshead Slides .....................................................25 Oil Stop Heads .........................................................25 Valve Chambers .......................................................25 Liner Clamp And Liners............................................26 Pistons......................................................................26 Piston Rod ................................................................26 Piston Washing System ...........................................26 Maintenance Of Valves ............................................26 Suction Strainer ........................................................27 SECTION 4...............................................................28

SECTION 1 DANGER NOTICES DANGERRead and understand the following DANGER NOTICES before moving or operating the pump or any pump package unit equipment. Reciprocating pumps are machines capable of producing high fluid pressures and flow rates and are designed to be used with proper care and caution by trained, experienced operators. TO AVOID PERSONAL INJURY, DEATH AND/OR EQUIPMENT DAMAGE, READ AND THOROUGHLY UNDERSTAND THE FOLLOWING DANGER NOTICES PLUS THE ENTIRE OPERATING AND SERVICE MANUAL BEFORE ATTEMPTING TO MOVE OR OPERATE THE PUMP. Contact a Gardner Denver service representative if you are unable to comply with any of the danger notices or procedures described in these documents. Closely examine the data plate upon pump delivery to become thoroughly familiar with the operating limits for this pump model. The pump must never be operated at speeds, pressures or horsepower exceeding the maximum values shown on the data plate or at speeds below the minimum shown. Failure to observe the operating limits shown on the data plate could result in personal injury, death, and/or equipment damage and will void the warranty. Alterations to the pump, or application of the pump outside the data plate limits, must not be made without Gardner Denver written approval together with a new data plate, as dangerous operating conditions could result. THE DANGER NOTICE AND DATA PLATES PROVIDED ON THE EQUIPMENT MUST NOT BE REMOVED, PAINTED OVER, HIDDEN OR DEFACED. They must be replaced if they become damaged or unreadable. Provisions should be made to have the following written danger notices plus the pump operating and service manual readily available to operators and maintenance personnel. In addition, copies of all pump system accessory component (e.g. pressure relief valve, pulsation dampener, suction stabilizer, engine, electric motor, etc.) operating and service manuals should be readily available for operator and maintenance personnel use. Read and follow all the precautions and instructions contained in these manuals. If any of these documents are lost or become illegible they must be replaced immediately. The danger notices plus the operating and service manuals should be reread periodically by both 15-600 operators and maintenance personnel to refresh their memories in safe procedures and practices. Keep in mind that full operator attention and alertness are required when operating high pressure pumping equipment. Operators should not begin or continue operations when tired, distracted or under the influence of alcohol or any type of prescription or nonprescription drugs. The timely replacement of expendable parts and any other worn or damaged parts can prevent equipment damage and possible injury. The original parts used in Gardner Denver pumps are designed and tested to exacting standards to provide high quality performance and durability. Your best insurance in maintaining these characteristics is to use genuine Gardner Denver replacement parts. A broad range of danger notices are covered on these pages, however, they cannot substitute for training, experience and common sense in the safe operation of high pressure pumping equipment. HAMMER LUG FASTENERS

DANGEROn pumps or pump package units equipped with hammer lug connectors and/or hammer lug valve covers the following precautions must be observed to avoid personal injury, death and/or equipment damage due to contact with the hammer, hammer bar, broken parts from the hammer, hammer bar or lugs or other objects propelled by hammer blows. When tightening or loosening hammer lug connectors and valve covers, operators or maintenance personnel should: Inspect the hammer, hammer lugs and hammer bar, if one is used, to insure they are all in good condition. Replace any of these parts which are cracked, damaged or badly worn. Wear safety shoes and goggles. Alert other personnel to move away from the area. Check to insure they have safe footing. Fully engage the hammer bar, if one is used, to prevent it from disengaging violently from the cover as a blow is struck. Wipe their hands and the hammer handle and maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking. Page 1

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

DANGERThe following precautions must be observed by operators and maintenance personnel to avoid personal injury, death and/or equipment damage from contact with the puller, hammer, wedge or broken parts from these components when using either a hydraulic or wedge valve seat puller: Hydraulic Puller Wear safety shoes and goggles. Chain or tie the jack down as it will jump violently when the valve seat disengages from the valve deck. Check to insure the pressure applied by the hydraulic pump does not exceed the hydraulic ram maximum pressure rating.

DANGERFailure to follow safe and proper pump, pump package or component lifting or moving procedures can lead to personal injury, death and/or equipment damage from shifting, falling or other unexpected or uncontrolled equipment movements.Make sure the hoist, lift truck, ropes, slings, spreader, or other lifting equipment you are using is in good condition and has a rated lifting capacity equal to or greater than the weight being lifted. Lifting devices must be checked frequently for condition and continued conformance to rated load capacity. They should then be tagged with the inspected capacity together with the date of inspection. Fully assembled pumps and pump package units are heavy and should only be moved using the specified lifting lugs or attachments. Many individual components have lifting eyes or lugs which must not be used to lift assemblies, as they are designed to bear the weight of the component only. Before lifting the individual component check to insure the lifting attachment is firmly secured to the component with undamaged, properly torqued fasteners, sound welds, or other secure attachments. Examine the lifting eyes, lugs, slots, holes or other projections to insure they are not cracked, otherwise damaged or badly worn. The repair of existing or addition of new welded lifting eyes, lugs or other projections should only be performed by experienced, qualified welders. Package units should be lifted with spreaders connected to the lifting attachments normally built into the package unit support skid. Packages too large to lift fully assembled should be separated into smaller

DANGERAll pump covers must be securely fastened in proper position at all times when the pump is operating to avoid personal injury or death from moving parts. In addition, all moving parts on the entire pump package, including but not limited to, the engine or motors, drive shafts, belts, chains, pulleys, gears, etc., must be equipped with guards or covers, which must also be securely fastened in proper position at all times when the equipment is operating.Covers and guards are intended to not only protect against personal injury or death, but to also protect the equipment from damage from foreign objects. 15-600

loads. For these smaller loads the lifting devices should be fastened to the lifting attachments normally built into the individual motor, engine, pump or transmission/torque converter, or their separate support skids. When lifting subassembled components, for example a suction stabilizer attached to suction piping or a discharge pulsation dampener attached to a strainer cross and piping, use special lifting slings designed to safely support the combined weight of the components. If a crane or hoist is being used to lift large components or assemblies, one or more persons should assist the operator from the ground with guide lines attached to the equipment being moved to properly position it and prevent uncontrolled movement. When you start to lift a pump, package unit, subassemblies or individual components and you observe the equipment is tilting, or appears unbalanced, lower the equipment and adjust the lifting device to eliminate these improper lifting conditions before proceeding to move the equipment. It is poor practice and dangerous to allow the equipment to pass over or close to your body or limbs. Be prepared to move quickly out of danger if equipment starts to fall, slip or move unexpectedly toward you. PRESSURIZED PUMP SYSTEMS

DANGERNever place a shut-off valve or any other component between the pump discharge connection and the pressure relief valve.Make sure the pressure relief valve is installed so any pressurized relief discharge from the valve is directed away from possible contact with people or equipment. The relief valve must be set to relieve at a pressure equal to or below the maximum pressure values shown on the pump data plate. However, if a component is used in the discharge system with a lower rated pressure capability than that listed on the pump data plate, the pressure relief valve must be set to relief valve must be set to relieve at a pressure equal to or below the rated capability of the lowest rated component. Before starting the pump every time, check to insure: The pressure relief valve is in good operating condition and has been set to the proper relief pressure. Any pipe line used to direct pressurized relief flow to another location, such as a collecting tank, is not blocked. The discharge system is not blocked and all the discharge line valves are open. Check all fluid end discharge system components including pipe, connections, elbows, threads, fasteners, hoses, etc., at least once every six months to confirm their structural adequacy. With time, wear, corrosion and fatigue can reduce the strength of all components. Magnetic iron and steel components should be checked with magnetic particle or dye penetrate crack detection equipment. Nonmagnetic materials should be checked for cracks with dye penetrants. All metallic components should also be visually checked during these inspections for signs of corrosion. If a component shows evidence of cracking or loss of material due to corrosion it must be replaced with a new part. Continually monitor suction and discharge hose assemblies when the pump is operating for leakage, kinking, abrasion, corrosion or any other signs of wear or damage. Page 3

DANGERFluids under high pressure can possess sufficient energy to cause personal injury, death and/or equipment damage either through direct contact with escaping fluid streams or by contact with loose objects the pressurized fluid propels.Operating a pump against a blocked or restricted discharge line can produce excessive pressures in the entire discharge system, which can damage or burst discharge system components.

DANGERNever operate a pump without a properly sized pressure relief valve located in the flowing discharge line immediately adjacent to the pump discharge connection.15-600

Worn or damaged hose assemblies should be replaced immediately. At least every six months examine hose assemblies internally for cut or bulged tube, obstructions and cleanliness. For segment style fittings, be sure that the hose butts up against the nipple shoulder, the band and retaining ring are properly set and tight and the segments are properly spaced. Check for proper gap between nut and socket or hex and socket. Nuts should swivel freely. Check the layline of the hose to be sure that the assembly is not twisted. Cap the ends of the hose with plastic covers to keep them clean until they are tested or reinstalled on the pump unit. Following this visual examination, the hose assembly should be hydrostatically tested, on test stands having adequate guards to protect the operator, per the hose manufacturers proof test procedure. Fluid end component inspections should be performed more frequently than every six months if pressures above 2,500 PSI are used in the discharge system or if corrosive, flammable or hot (over 110 F) fluids are being pumped. Proper stuffing box packing selection is important for safe pump operation. Contact a Gardner Denver service representative for assistance in selecting the proper packing before beginning operation. Before starting the pump the first time and periodically thereafter check the pump, suction and discharge system fastener torques versus the values listed on page 12 to insure proper tightness. Over and under torquing can damage threaded pipes, connections and fasteners, which may lead to component damage and/or failure. Replace all components found to be damaged or defective. On pumps equipped with stuffing boxes, the gland must be engaged by at least three (3) threads to hold the discharge pressure of the pump. Block the crankshaft from turning and make certain that all pump drive motor or engine start switches or starter controls are clearly tagged with warnings not to start the pump while repair work is in process.

Whenever the pump is operating, continually monitor the entire suction, discharge and pump lubricating systems for leaks. Thoroughly investigate the cause for leakage and do not operate the pump until the cause of the leak has been corrected. Replace any parts which are found to be damaged or defective. When a gasketed joint is disassembled for any reason, discard the used gasket and replace it with a new, genuine Gardner Denver gasket before reassembling the joint. Due to the high working pressures contained by the fluid cylinder, discharge manifold and discharge piping, welding on these components is not recommended. If welding on the discharge system cannot be avoided, only experienced, qualified welders should be used. In addition, the welded part should be hydrostatically proof tested in the shop with water or hydraulic fluid to one and one half times maximum discharge system working pressure, with no observable fluid leakage, before the part is reinstalled in the pump system. In summary, high pressure fluid streams can possess sufficient energy to cause personal injury, death and/or equipment damage. These results can occur either through direct contact with the fluid stream or by contact with loose objects the fluid stream has propelled, if the pump system is improperly used, or if the fluid is misdirected, or allowed to escape from defective or improperly maintained equipment. FLAMMABLE, HOT, COLD OR CORROSIVE FLUID PUMPING

DANGERExtreme caution must be exercised by trained and experienced operators when flammable, hot, cold or corrosive fluids are being pumped in order to avoid personal injury, death and/or equipment damage due to explosion, fire, burn, extreme cold or chemical attack.Never operate a pump which is pumping hydrocarbons or other flammable, hot, cold, or corrosive fluids when any part of the pump, suction system or discharge system is leaking. Stop the pump immediately if any leakage, other than a few drops per minute of packing weepage, is observed. Keep all flame, sparks, or hot objects away from any part of the pump, suction system, or discharge system. Shield the pump, suction system and discharge system to prevent any flammable, hot, cold Page 4

DANGERDo not attempt to service, repair, or adjust the plunger packing or otherwise work on the pump while the unit is operating. Shut off the pump drive motor or engine and relieve the fluid pressure in the pump suction and discharge systems before any work or investigation is performed on the pump or pump systems.15-600

or corrosive fluid leakage from dripping or spraying on any components, flame, sparks, hot objects or people. Inspect the plungers, packing, gaskets and seals for fluid leakage frequently and replace all worn or leaking parts. Selection of the proper gaskets, seals and stuffing box packing is even more critical when flammable, hot, cold or corrosive fluids are being pumped than when other, inherently less dangerous fluids are used. Contact a Gardner Denver service representative for assistance in selecting the proper gaskets, seals and packing before beginning operation. Since some packing weepage into the cradle area is inevitable, the drain at the bottom of the cradle must be connected to a drain line which conducts the fluid leakage to a collection container located in a protected area. The entire drain system and container must be constructed of materials resistant to attack from the pumped fluid or from explosion or fire of the pumped fluid. Heavy duty cradle covers must be securely fastened in the proper position on the pump at all times when the pump is operating. If the pumped fluid releases harmful, explosive or flammable vapors the covers must be vented to conduct the fumes away from the pump unit to a nonhazardous area. Before beginning pumping operations or starting the pump power source (whether an engine or electric motor) check the atmosphere all around the pumping site for the presence of flammable or explosive vapors. Do not begin operation and stop ongoing operation if flammable or explosive vapors are detected. Hot surfaces, sparks, electric current or engine exhaust could ignite flammable or explosive vapors. Each engine used as a power source on pumping units where flammable or explosive vapors could form should be equipped with an air inlet shut-off. If flammable or explosive vapors are present in the pumping site atmosphere, an engine could continue to run on these vapors even after the engine fuel line is shut-off if an air inlet shut-off is not used. In addition, on pumping units used where flammable or explosive vapors could form, all electric motors used as power sources must be of explosion proof construction and all electrical components and wiring must meet the current National Electrical Code for explosive atmospheres. These precautions must be taken to avoid possible personal injury, death and/or equipment damage from explosion, fire or burns.

DANGERExtreme caution must be exercised if any type of wand, gun, nozzle or any other pressure and flow directing device is attached to the pump discharge system for use in jetting, blasting, cleaning, etc. This type of equipment must be used with utmost care by trained, experienced operators. High pressure fluid streams can either by direct contact or by propelling loose objects, cause serious personal injury or death to the operators and/or other persons.Pressure or flow directing devices often receive pressurized flow through flexible hoses, which can burst if they are kinked, cut, abraded or are otherwise worn, damaged or pressured above their rated capacity. Protect the hose and connections from damage by people, objects and vehicles. A broken, cut or otherwise burst hose can release pressurized fluid which may cause personal injury, death and/or equipment damage. High pressure fluid from hand held or hand directed pressure and flow directing devices may overpower an operators ability to control or direct the device, which could lead to personal injury, death and/or equipment damage. The operator must brace against the backward thrust of a hand held device. In addition, a safety harness or safety net must be used when working in an area where the operator could be injured in a fall. Stand to the side of any tubing or container being sprayed to avoid back spray and never operate a hand held device above shoulder level. Never direct the pressurized fluid stream at yourself or any other person, control valves, the pump, pump drive, suction or discharge systems. The pressurized stream can cause serious personal injury or death and can also change valve or control settings which could dangerously increase the delivery pressure to the pressure and flow directing device. When operating a pressure and flow directing device, use only equipment which automatically shuts off flow when an operator releases hand or foot pressure on the pressurized flow trigger control to prevent injury if the operator is overpowered or becomes disabled.

The equipment must be shut down and the system pressure released before changing or disconnecting wands, nozzles, guns, hoses, connections or any other pressurized system components. All pressure containing devices including wands, nozzles, guns, connections, etc., plus all automatic shut-off, pressure and control equipment should be treated with care. Protect them from damage by people, objects and vehicles. Never lay them in dirt, mud, ice or other loose material which could plug the fluid opening or interfere with their operation. Never use the wand, nozzle, gun, etc. to pry loose material off items being cleaned. Before starting operation in a cold environment, check to make sure there is no ice in the fluid system and repeat this inspection each time before operation is restarted. Before purchasing wands, nozzles, guns, connections, and hose, etc., manufacturers of these components should be contacted for detailed information on the design and safety features incorporated in their products. After careful study of various manufacturers products, we recommend that only those wands, nozzles, guns, connections and hose, etc., be considered for purchase that you judge to offer the highest quality of design, construction and safety, since these components are among the most critical to the safe operation of high pressure liquid jetting, blasting and cleaning equipment. After you have selected and purchased these components, follow the manufacturers instructions completely in their use.

SECTION 2 INSTALLATION & OPERATING INSTRUCTIONSFOR GARDNER DENVER PZ SERIES & PXL SINGLE ACTING POWER PUMPS Reference to Parts List covering the Model Pump being serviced is recommended in connection with this Instruction Manual. Repair Parts Lists with Sectional Views are available from any Gardner Denver Sales and Service Office. When ordering parts, always give size and serial number of pump. Always use genuine Gardner Denver parts. For efficient, factory-trained service, consult a Gardner Denver Service Specialist. START-UP Pumps are shipped from the factory without oil in the crankcase. The hood should be removed and the power end examined and cleaned if necessary. The pump may have been in storage or in the yard for sometime and as a consequence dirt may have entered the crankcase. Parts may have been robbed from the pump during storage and not replaced. All nuts and screws should be tightened. Be sure all valves in the discharge line are open. No valve should be installed between the pump and pressure relief valve in discharge line. To prevent excessive wear on the fluid pistons and packing when starting, remove a suction valve cover plate on each side of the fluid end and prime the pump. Pump should be started slowly, if possible, and should be operated for several hours with practically no discharge pressure. Check oil level as it may be necessary to add a small quantity of oil to compensate for that adhering to the walls of the crankcase the moving parts. The pump may then gradually be brought up to full speed and full working pressure. Watch for undue heating or abnormal noise in the working parts. Check all joints in the suction line to be sure there are no air leaks.

DANGERIf the drive is not to be removed, it is recommended that the air line to the clutch be disconnected to prevent accidental starting of the pump.LOCATION - Pump should be set level and solidly supported. The drive should be accurately aligned. Pump should be placed as close to the slush pit as possible to keep the suction line short and direct. Locate pump as low as possible to maintain a minimum suction lift to the centrifugal charging pump which is used because of the high speed of this type of mud pump. When the pump skid or master skid is to be bolted or welded to a platform or deck in the field, it is necessary that the following Final Shimming Procedure be followed. Final Shimming Procedure - After the pump skid or master skid has been bolted or welded to a stationary platform or deck, proceed as follows: a. Remove the cap screws used to secure the pump frame to its skid. At each foot where a space exists between foot and skid, place a dial indicator on the frame foot and skid as shown in FIGURE 1. Set dial to ZERO. Place shims between frame foot and skid where space exists so the dial indicator shows the frame has been raised approximately .005 to .010 inches (.126 to .254 mm). Securely tighten the frame to skid cap screws. If the proper number of shims were used, the dial indicator should return to within +/-.003 inches (.076 mm) of zero. If not, repeat the procedure changing number of shims used.

DANGERWhen working on any pump, be certain there is no fluid pressure on either the suction or discharge side. Pressure on the fluid end might move the pump and cause damage or injury to personnel. It is recommended that all suction valve covers be removed to avoid fluid pressure building up against the pistons or plungers.

Never install a shutoff valve in the line between the pressure relief valve and the pump discharge manifold.If more than one pump is used, a pressure release valve should be furnished for each pump. A handoperated pressure release valve should be installed in discharge line following the relief valve, with discharge line leading to mud tank. This valve is used to bleed air from discharge line in starting. It is also used to relieve pressure in starting more than one pump in parallel. SURGE CHAMBER - A surge chamber is essential. One MUST be used for protection to surface equipment and to reduce pulsations when pumping gaseous mud. A nitrogen-charged pressure-bag type surge chamber is recommended. The surge chamber must be kept properly charged, as instructed by the manufacturer. STARTING A NEW PUMP - It is recommended that the drive be arranged to turn the pump in the direction indicated by arrow shown on the sectional view in this book, on outline prints, and indicated on pump frame. This book provides for crosshead load to be carried on the lower side. This means better lubrication and quiet operation. Lube oil pumps are not automatice reversing. If the PZ series or the PXL pumps are to be run in reverse direction, refer to Lube Oil Pump. Pumps are shipped from the factory without oil in the crankcase. The hood should be removed and the power end examined and cleaned if necessary. The pump may have been in storage or in the yard for some time, and as a consequence, dirt may have entered the crankcase. Drain all water accumulated in the bottom of the crankcase. Fill crankcase with oil of proper grade to the proper level. Quantity shown on lubrication data plate indicates the approximate oil requirements. All nuts and cap screws should be checked for tightness. It is recommended that the fluid end of the pump be primed to prevent excessive wear on the fluid pistons and liners when starting. PRIMING IS IMPORTANT! IT LUBRICATES THE PISTONS IN THE LINERS. Pump should be started slowly but not run below half of rated speed. Recheck oil level as it may be necessary to add a small quantity of oil to crankcase and the moving parts. The pump may then be gradually brought up to full speed and full working pressure. Check all joints in the suction line to be sure there are no air leaks. Page 8

SUCTION LINE - Suction pipe or hose to centrifugal charging pump should be a minimum of 12 inches (304.8 mm) diameter and as short as possible. Always use eccentric reducers when reducing suction pipe size. Suction line should slope up toward the charging pump at uniform grade to prevent air pockets being formed. Suction line must be absolutely tight as any air leaking into the line will reduce the capacity of the pump and cause a hydraulic hammer or knock. If it is necessary to have bends in the suction line they should have long radius sweeps and be kept to a minimum in quantity. 10 PSI - 40 PSI suction required. Suction line should be supported near centrifugal charging pump to keep strain from breaking the casing at suction flange. At least one section of hose in the suction line is desirable to isolate pulsations or vibration. Total suction line should be as short as installation conditions permit. THIS IS IMPORTANT. A suction strainer is recommended for the suction line of every pump. It must be checked frequently and cleaned whenever necessary. A commercial strainer may be installed in suction line ahead of the pump. 2 It is recommended that a 50 PSI (3.515 kg/cm ) gauge with a needle valve for protection be installed in the suction line at the discharge of the centrifugal charging pump. This gauge will indicate if pump is charging or if suction valves are not working properly. RELIEF VALVES - The pump should be protected from excess discharge pressure by a 3 inch (76.2 mm) relief valve. This valve should be installed in a vertical position in a tee mounted directly onto either end of discharge manifold or discharge cross.

LUBRICATION - All power end working parts are lubricated by the oil in the crankcase. Check oil level frequently. Selection of oil is to be taken from the recommendations given in FIGURE 2 and on the pump data plate. Local conditions and practice may also influence the selection. Essential additives are foam and oxidation inhibitors. Oil is to be added as required to maintain oil level near the top of the oil level indicator on the side of the frame. 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 needed to meet these requirements. LUBRICATION SCHEDULEFrequency Daily Type *A.P.I. Type GL-5 Lubricant 50% Water Plus 50% Water Soluble Oil *A.P.I. Type GL-5 Lubricant Procedure Check oil level with pump running. Check fluid level in piston wash tank.

Failure to follow these lubrication requirements will void the warranty. Some operating conditions and/or oil brands produce excessive oil foaming, even when the specified GL-5 oils containing antifoaming additives are used. Oil foaming can cause pump damage, as oil bubbles will not lubricate moving parts properly. If significant oil foaming occurs, contact Gardner Denver Marketing or Service, (217) 222-5400, for the current factory recommended defoamant to be added to the lubricating oil. Oil must have antiwear, antifoaming, noncorrosive and rust inhibiting additives.

Oil is constantly circulated through a renewable element filter and then through a heat exchanger, when one is used, by means of a rotary pump driven from the main gear. Oil is discharged into an elevated oil feed trough, from which it is conducted to jackshaft and main bearings. Oil also flows from the trough to lubricate the connecting rod bearings. Operating temperatures of the oil should be kept below o o 200 F (93.3 C) to reduce oxidation.

OIL CAPACITIES Pumps Without Heat ExchangerModel PZG PZH PZJ PZK PZL PXL Cast Frame 60 Gal. (227.1 Liters) 60 Gal. (227.1 Liters) 70 Gal. (264.9 Liters) 85 Gal. (321.8 Liters) 85 Gal. (321.8 Liters) 85 Gal. (321.8 Liters) Fabricated Frame None 85 Gal. (321.8 Liters) 105 Gal. (397.4 Liters) 100 Gal. (378.5 Liters) 100 Gal. (378.5 Liters) None

Pumps With Heat ExchangerModel PZG PZH PZJ PZK PZL PXL Cast Frame 41 Gal. (155.2 Liters) 41 Gal. (155.2 Liters) 50 Gal. (189.3 Liters) 85 Gal. (321.8 Liters) 85 Gal. (321.8 Liters) 85 Gal. (321.8 Liters) Fabricated Frame None 65 Gal. (321.8 Liters) 85 Gal. (397.4 Liters) None None None

Time between oil changes depends upon local and/or operating conditions. Under normal circumstances, if the crankcase is kept clean, it should not be necessary to change the oil more than once in 1000 hours of operation. Many operators change oil after each well drilled. Oil should be changed if found to be dirty or contaminated with mud or water, as the oil lubricated roller bearings will be damaged by contamination. An oil change is comparatively inexpensive, as the approximate crankcase capacities are shown above. In order to assure proper lubrication, the PZG, PZH & PZJ pumps should not be run under 10 RPM for more than a few minutes at a time without providing additional lubrication from an extra external oil pump. The PZK, PZL & PXL pumps should not be run under 40 RPM. The oils normally used in large mud pumps are quite viscous at lower temperatures. When starting cold, the pump should be started slowly and brought up to operating speed slowly. This practice will assure proper lubrication of all working parts before pump is fully loaded. OIL FILTER - A replaceable element oil filter is located inside the pump crankcase. Filter mounting flange is on oil is changed or every 1000 hours of operation. Filter element is protected from excessive internal oil pressure by a relief valve between it and the oil pump. Filter element should be replaced each time crankcase oil is changed or every 1,000 hours of operation. The filter element is protected from excessive internal oil pressure by a relief valve between it and the oil pump.

HEAT EXCHANGER (Optional Equipment) - For PZ series & PXL pumps a bronze heat exchanger can be provided to keep crankcase oil temperature at 160 F (71.1 C) by means of an automatic water control valve. This valve has a sensing probe in the crankcase oil, and it monitors water to the heat exchanger to maintain oil temperature within close limits. Water must be drained from the heat exchanger during freezing weather. Ruptured water tubes will admit water into the oil, with resulting damage to working parts of the pump. Cooling water can be drained from the heat exchanger by removing water connections and blowing compressed air into upper opening. Water will then flow from the lower opening. Air is necessary, as water will not otherwise drain due to small size of tubes, capillary attraction, and the horizontal position of the heat exchanger mounting. Water should not be admitted to the heat exchanger as long as oil temperatures do not exceed 160 F(71.1 C). A dial thermometer is standard equipment on all PZ series and PXL pumps. Salt water can be used for cooling. Zinc anode plugs are provided for corrosion protection. These plugs are to be replaced when they have been corroded away. DIRECTION OF ROTATION - The PZ series & PXL pumps MUST be driven in the direction as shown by arrow on sectional view, outline drawing and on pump frame. The oil pump on PZG, PZH and PZJ models is a nonreversible pump without adjustments described in Lube Oil Pump, page 24.

Running the pump in the prescribed direction insures proper lubrication and quiet operation as the load on the crosshead will be carried on the lower side. CROSSHEAD DRAINS - PZ series & PXL pumps are equipped with two plugged drain openings below and in front of the crossheads. These openings are to drain any possible leakage from the oil stop head packings which collects in a small reservoir built into the frame. This area should be drained daily.

It is recommended that these openings be piped together and a valve installed to simplify the daily draining. Failure to drain this area could result in drilling mud in the power end and possible premature failure. OPERATION - For normal drilling operation, the pumps are to be run at the ratings listed on pages 12 thru 15. In no case should pressure exceed that shown for each diameter piston - to do so would subject working parts to operating loads in excess of those for which they were designed, resulting in reduced life.

MAINTENANCE SCHEDULE FOR GARDNER DENVER PZ SERIES AND PXL PUMPS: Daily: 1. Inspect condition of piston and liners. They should be run until leakage of fluid is visible or becomes excessive. 2. Clean inside frame cradle. Monthly: 3. Clean and refill piston wash tank after excessive contamination. 4. Check piston wash baffle, make certain nozzles are not clogged. 5. Check pulsation dampener for proper charge. Weekly: Every 1000 Hours: 1. Remove valve covers and gaskets. Replace if cut or warn. 2. Check fluid valves and seats for wear. Replace cut or worn inserts and valves. 3. Inspect urethane bushing in suction discharge valve guides and replace if worn. and 1. Clean frame oil drain magnet during oil change. 2. Clean frame oil drain plug magnets located in front of crossheads and clean the oil passage. 3. Clean inside frame during regular oil change. 1. Check all fluid cylinder studs and nuts for tightness. 2. Remove and clean discharge cross strainer. 3. Check condition of oil stop head seals and replace if worn or leaking excessively. Every Two Weeks: 1. Remove valve cover locks. Clean threads on locks and rings. Coat threads with moly coat thread compound or heavy-duty lead base thread compound. Replace if they are worn or cracked.

MODEL PZG 550 H.P. TRIPLEX MUD PUMP 13.25 507 1919 1673 117.6 11.43 437 1654 1940 136.4 9.73 373 1412 2277 160.1 8.18 313 1185 2710 190.5 6.78 259 980 3279 230.5 5.49 210 795 4048 284.6

Weight Complete Pump ............................................................................................................................. 17,410 lbs. (7897.04 kg) Gear Ratio .......................................................................................................................................................................... 4.625 to 1 Length Over Skid ........................................................................................................................................ 120 Inches (3048.0 mm) Width Over Skid ............................................................................................................................................. 50 Inches (1270.0 mm 3 3 3 3 3 3 3 3 7 6 1/2 6 6 5 1/2 5 4 1/2 4 177.8 165.1 158.8 152.4 139.7 127.0 114.3 101.6 8 8 8 8 8 8 8 8 203.2 203.2 203.2 203.2 203.2 203.2 203.2 203.2 4.0 3.45 3.19 2.94 2.47 2.04 1.65 1.31 MODEL PZH 750 H.P. TRIPLEX MUD PUMP 15.14 580 2196 1996 140.3 13.06 500 1893 2315 162.8 12.08 462 1749 2504 176.0 11.13 426 1613 2717 191.0 9.35 358 1355 3233 227.3 7.72 296 1120 3912 275.1 6.25 240 908 4830 339.6 4.96 189 715 5000* 351.5* 76,817 76,817 76,817 76,817 76,817 76,817 76,817 62,832* 34,844 34,844 34,844 34,844 34,844 34,844 34,844 28,510* 145 145 145 145 145 145 145 145 652 652 652 652 652 652 652 652 750 750 750 750 750 750 750 613*

Weight Complete Pump ............................................................................................................................. 21,650 lbs. (9820.27 kg) Gear Ratio .............................................................................................................................................................................. 4.5 to 1 Gear Ratio .............................................................................................................................................................................. 4.5 to 1 Length Over Skid ................................................................................................................................... 193.62 Inches (4917.9 mm) Width Over Skid ............................................................................................................................................. 89 Inches (2260.6 mm

MODEL PZJ 1,000 H.P. TRIPLEX MUD PUMP 17.03 585 2215 2639 185.5 14.69 504 1908 3060 215.1 13.59 466 1764 3310 232.7 12.53 430 1628 3592 252.5 10.52 361 1367 4274 300.5 8.70 298 1128 5000* 315.5* 7.04 242 916 5000* 315.5* 5.53 191 723 5000* 315.5*

Weight Complete Pump .......................................................................................................................... 26,500 lbs. (12,020.19 kg) Gear Ratio ............................................................................................................................................................................ 4.48 to 1 Length Over Skid ............................................................................................................................... 224.12 Inches (5692.648 mm) Width Over Skid ............................................................................................................................................. 96 Inches (2438.0 mm Width Over Jackshaft ............................................................................................................................. 80.20 Inches (2037.08 mm) 3 3 3 3 7 6 1/2 6 5 1/2 177.8 165.1 152.4 139.7 10 10 10 10 254 254 254 254 5.0 4.31 3.67 3.09 MODEL PZK 1,350 H.P. TRIPLEX MUD PUMP 18.93 575 2177 3624 254.8 139,474 16.31 496 1878 4203 295.5 139,474 13.89 422 1508 4933 346.8 139,474 11.70 355 1344 5000* 351.5* 118,791* 63,264 63,264 63,264 53,884* 115 115 115 115 504 504 504 504 1350 1350 1350 1150*

Weight Complete Pump ........................................................................................................................... 40,500 lbs. (18370.48 kg) Gear Ratio .............................................................................................................................................................................. 4.5 to 1 Gear Ratio ............................................................................................................................................................................ 4.38 to 1 Length Over Skid ..................................................................................................................................... 222.5 Inches (5651.5 mm) Width Over Skid ............................................................................................................................................. 96 Inches (2438.4 mm Width Over Jackshaft ................................................................................................................................... 104 Inches (2641.6 mm

MODEL PZL 1,600 H.P. TRIPLEX MUD PUMP 20.82 632 2392 3905 274.5 150,275 68,164 17.94 545 2063 4529 318.4 150,275 68,164 15.29 465 1760 5000* 351.5* 141,372* 64,126* 12.83 390 1476 5000* 351.5* 118,791* 53,884*

Weight Complete Pump .......................................................................................................................... 40,500 lbs. (18,370.48 kg) Gear Ratio ............................................................................................................................................................................ 4.38 to 1 Length Over Skid ..................................................................................................................................... 222.5 Inches (5651.5 mm) Width Over Skid ............................................................................................................................................. 96 Inches (2438.4 mm Width Over Jackshaft ................................................................................................................................... 104 Inches (2641.6 mm 3 3 3 3 3 7 6 1/2 6 5 1/2 5 177.8 165.1 152.4 139.7 127.0 11 11 11 11 11 MODEL PZL 1,600 H.P. TRIPLEX MUD PUMP (HIGH PRESSURE) 279.4 5.5 20.82 632 2392 3905 274.5 150,300 279.4 4.74 17.94 545 2063 4529 318.4 150,300 279.4 4.04 15.29 465 1760 5316 373.7 150,300 279.4 3.40 12.83 390 1476 6328 444.8 150,300 279.4 2.80 10.60 322 1219 7500* 527.2* 147,262* 68,164 68,164 68,164 68,164 66,797* 115 115 115 115 115 504 504 504 504 504 1600 1600 1600 1600 1565*

Weight Complete Pump .......................................................................................................................... 41,750 lbs. (18,937.47 kg) Gear Ratio ............................................................................................................................................................................ 4.38 to 1 Length Over Skid ..................................................................................................................................... 222.5 Inches (5651.5 mm) Width Over Skid ............................................................................................................................................. 96 Inches (2438.4 mm Width Over Jackshaft ................................................................................................................................... 104 Inches (2641.6 mm

MODEL PXL 2,000 H.P. TRIPLEX MUD PUMP 20.82 632 2392 4882 343.2 187,875 85,219 17.94 545 2063 5662 298.0 187,875 85,219 15.29 465 1760 6645 467.1 187,875 85,219 12.83 390 1476 7500* 527.2* 178,125* 80,797* 10.60 322 1219 7500* 527.2* 147,262* 66,797*

Weight Complete Pump .......................................................................................................................... 46,250 lbs. (20,978.63 kg) Gear Ratio ............................................................................................................................................................................ 4.38 to 1 Length Over Skid ..................................................................................................................................... 222.5 Inches (5651.5 mm) Width Over Skid ............................................................................................................................................. 96 Inches (2438.4 mm Width Over Jackshaft ................................................................................................................................... 104 Inches (2641.6 mm

SECTION 3 ROUTINE MAINTENANCE & SERVICE INSTRUCTIONSRemove hood and crosshead inspection plates for access to working parts. Before working on inside of crankcase, it is necessary to drain the oil. Lube oil pump mounting brackets and piping connections are below the oil level. Mark all parts during dismantling so they can be returned to their original position during reassembly. It is highly recommended that pump be removed to a machine shop if major work is to be done on power end. spacer ring between the inner race and the shoulder on the shaft. If the jackshaft bearing is to be replaced, the outer race and roller assembly can be driven or pressed out of the bearing housing. The jackshaft bearings should be replaced if any of the rollers or races shows damage or if they are excessively worn. A noisy bearing indicates bearing damage, requiring replacement. Check clearances by inserting feeler gauge between the roller and inner race with bearing assembled on the shaft and in the housing. This check can be made with the bearing temporarily assembled out of the pump, but with inner race on jackshaft. See recommended running clearances on pages 28, 29, or 30. To mount the new bearings, heat the inner race in oil to about 300 F (148.8 C) and slip it in on the shaft against the bearing spacer ring. Be certain the spacer ring is in place with the chamfered end of the bore over the large fillet on the jackshaft. The inner race and the spacer are to be assembled snugly against the shaft shoulder. The shaft can be reinstalled in the frame. To mount a new oil seal wear sleeve, heat the sleeve in oil to about 300 F (148.8 C) and slip it on the shaft. See FIGURE 13, page 17.

JACKSHAFT - To remove the jackshaft, it is necessary to remove all sheaves from the jackshaft. Then remove bearing end plates and bearing housings from both sides of pump. Support each end of jackshaft while removing bearing housings. The jackshaft can be moved horizontally until the pinion teeth clear the teeth of the eccentric gear. The jackshaft can now be removed from either side of the pump. The jackshaft bearings are of the straight roller type with roller and cage assembly held in the flanged outer race. The inner race is not flanged. The outer race and roller assembly will slide over the inner race which remains on the jackshaft. Both bearings are identical. The straight roller bearings permit the jackshaft to float endwise. Thrust loads are carried on the spherical main bearings. Main bearings will be covered as a separate item. The safest way to remove the inner race of the jackshaft bearing from the shaft is by the careful use of heat. Do not overheat to the point where race is discolored. Be careful not to damage the bearing 15-600

To reassemble the jackshaft in the pump, it is necessary to reverse procedure of removal. The teeth of the pinion can mesh in only one direction, therefore, the jackshaft is not interchangeable end for end in the pump unless gear and eccentric assembly is also reversed. Reversal of the complete gearset is permissible after gear or pinion teeth become badly worn. Since gear is not on centerline of the frame, it is necessary to move the oil pump and filter from original position to the opposite side of the frame and repipe as required. Required direction of rotation of the pump provides that inner ends or apex of gear and pinion teeth lead. This means that when viewing from the hood opening, the inner ends of the gear teeth point upward toward the jackshaft and the inner ends of the pinion teeth point toward the gear. Gears may be reversed, but direction of rotation of the pump MUST NOT BE REVERSED. See paragraph Lube Oil Pump on the 15-600

following page. Pump should be run in the direction shown on sectional view and indicated by arrow on outline print and frame. Apex of teeth will follow after gearset has been reversed. After jackshaft is in place with the pinion in mesh with the gear, install the bearing housings with the outer bearing race and roller assemblies in them. Be careful to keep dirt from the bearings during assembly. The housing is to be started on the bearing and in the bore of the frame and lightly driven in. Be sure the gasket is on the housing. Long threaded studs may be used to pull the housing into the frame bore. It is well to work both housings at the same time after they have been well started over the bearing inner race. This will minimize end thrust on the gear teeth. Before assembling bearing plates into the frame, the bearing oil troughs should be installed. The bearing housing can be rotated in the frame, making it easy to Page 17

level oil trough properly. Top of oil trough is to be level. The PZG pump does not have oil trough. Outer oil seals are to be placed in the bearing end plate after it is bolted to the bearing housing and frame. Coat inside of oil seal liberally with bearing grease. The seal is to be installed with garter spring to inside, toward bearing. Permanently bolt jackshaft bearing housings and their end plates to the frame. LUBE OIL PUMP The lube oil pump, part number 46C21, used in the PZG, PZH and PZJ pumps can be reversed in direction when the complete gear sets are reversed after the following procedure is completed. Remove the oil pump with standard left hand helix drive gear from the pump frame. Remove the drive gear from the oil pump shaft. Remove the end cap from the oil pump opposite the shaft end, remove the drain plug screw opposite the oil pump discharge port. Install the drain plug screw in the o hole provided 180 or opposite from the suction port. Reverse the suction and discharge lines to the lube oil pump and reverse the data tag IN ROTATION OUT. The drain plug screw must be installed in the pump body opposite the oil pump discharge port. Replace the end cap. Install the optional right hand helix drive gear on the oil pump shaft. Install the oil pump and gear assembly on alternate mounting pad in the pump sump to mesh with reversed eccentric gear. The lube oil pump, part numbers 46C58 (previous production) and 201PAH188 (current production), used in the PZK, PZL & PXL pumps can be reversed in direction without modification to the pump. The oil flow through the pump will reverse direction when shaft is rotated in reverse. Viewing the oil pump 46C58 from the shaft end, rotating the shaft clockwise, the right hand pump opening is the inlet. When rotating shaft counterclockwise, the left hand opening is the inlet and the right hand opening becomes the outlet. When shaft rotation of the 201PAH188 oil pump changes direction, the direction of flow changes without changing inlet and outlet port positions. When reversing the complete gear sets on PZK, PZL and PXL pumps, the left hand helix pump drive gear must be replaced with an optional right hand helix drive gear. Install the oil pump and drive gear assembly on the alternate sump mounting pad to mesh with the reversed eccentric gear. CONNECTING RODS The connecting rods are split into body and cap, and bolted together without shims. y.

This construction is used to simplify installation and/or removal of eccentric and gear assembly. The upper connecting rod bolt is inserted from the cap side to avoid interference with jackshaft. The lower bolt is inserted from body side to make nut easily accessible. Crosshead pins with bearing inner races can be removed without disturbing the connecting rods on PZG, PZH and PZJ pumps. On the PZK, PZL & PXL pumps, the hood must be removed and the connecting rods loosened from the cap and parted by about one inch (25.4 mm) before the center crosshead pin will clear the outside connecting rod. Always protect crosshead slide in frame by placing a block of wood under small end of connecting rod. If slide should be accidently damaged, be certain to stone damaged area so no metal projects above slide surface. DO NOT USE EMERY CLOTH. When caps are removed, the bodies of the connecting rods can be supported by wiring or tying them to cap screws temporarily screwed into hood ledge above them. Do not damage hood gasket surface. See FIGURE 14. Remove eccentric bearing retainers from the connecting rod body and cap before cap is removed. Replace retainers after connecting rods have been reassembled. Be sure to wire the cap screws securely. Connecting rod bolt nuts are to be tightened to recommended torque shown on pages 31 and 32. The Pal locknuts are to be driven against nut by hand and then tightened 1/3 to 1/2 turn.

WARNINGBe sure to remove the oil pump drive pinion when removing or replacing the eccentric and gear asembly to avoid bending the oil pump shaft when the gear is removed.Eccentric and shaft are made in one piece. Eccentric and gear assembly is to be removed from the frame for the following reasons: (a) Assembly is to be reversed after gear is worn. (b) Gear is to be replaced. (c) One or more eccentric bearings are to be replaced. (d) Eccentric is to be replaced. Procedure For Removal: 1. Remove connecting rod caps and support the rods.FIGURE 15 ECCENTRIC GEAR ASSEMBLY SUPPORT

spacer blocks are marked to assure reassembly in original position. 5. Loosen main bearing retainer plate screws in ends of eccentric shaft. Do not remove the retainer plate screws. Leave about 1/4 (6 mm) space between eccentric shaft and retainer plates. Spread frame slot approximately 1/64 (.4 mm) by means of hydraulic or screw jacks (FIGURE 15, page 19). Be sure to protect faces of frame slots against damage from jacks. This is important. Support eccentric and gear assembly in original position by means of a sling, hoist or blocks (FIGURE 15, page 19).2 Connect a 10,000 PSI (703.1 kg/cm )hydraulic oil pump (BlackHawk P76 or equivalent) to 3/8 pipe tap in end of eccentric shaft after removing protective plug. There is a clearance hole through the retainer plate.

MAIN BEARINGS - These bearings are of the doublerow spherical type. Inner race has a tapered bore. Main bearings can be replaced without removing eccentric assembly from the pump and without disturbing connecting rods. Remove bearings with cartridges from the eccentric shaft and frame as outlined in procedure covering removal of eccentric and gear assembly. Be sure to support eccentric securely in its original location. Remove lube oil pump gear to protect oil pump shaft as main gear might move during this operation. 15-600

22. Replace lube oil pump. Put the hood back in place. Be sure the gasket is in good condition and in proper location. Bolt down securely. Use grease on frame flange to help keep hood gasket in place. 23. Do not forget to replace or renew the crankcase oil. Now is a good time for an oil change and a new filter element to protect the new bearings just installed. CROSSHEAD PINS Procedure For Removal of Outer Crosshead Pins 1. Cut wire and remove retainer plate to crosshead cap screws and use these as jack screws in tapped holes in plate to pull pins. A little persuasion with a drift driven against the crosshead body and close to the large end of pin will help loosen the pin.

Procedure For Removal of Center Crosshead Pin 1. Remove outer crosshead next to large end of center crosshead pin to give room to remove pin from center crosshead. Protect crosshead slide in frame with a block of wood. Rotate pump until center crosshead is at end of its stroke toward fluid cylinder. Remove center crosshead pin as described above for the two outer pins.

PUSH RODS - Push rods can be removed from the crossheads by wo