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GARDNER DENVER® Version 12 April 2002

SINGLE ACTING PUMP MODELS PZG – 7” PZH – 8” PZJ – 9” PZK – 10” PZL – 11” PXL – 11”

Downloaded from www.Manualslib.com manuals search engine 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 you’ll 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:

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: Factory: Gardner Denver Gardner Denver Master Distribution Center 1800 Gardner Expressway 5585 East Shelby Drive Quincy, IL 62301 Memphis, TN 38141 Phone: (217) 222-5400 Phone: (901) 542-6100 Fax: (217) 224-7814 Fax: (901) 542-6159

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).

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.

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 day- to-day operation, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and minimum downtime.

Downloaded from www.Manualslib.com manuals search engine 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 Maintenance Schedule.............................................11

SECTION 1................................................................ 1 Lube Oil Pump..........................................................18

Pressurized Pump Systems ...................................... 3 Main Bearings...........................................................21

Flammable, Hot, Cold Or Corrosive Fluidpumping.... 4 Crosshead Pins ........................................................24

Starting A New Pump ................................................ 8 Piston Rod ................................................................26

Downloaded from www.Manualslib.com manuals search engine SECTION 1 DANGER NOTICES operators and maintenance personnel to refresh their DANGER memories in safe procedures and practices. Read and understand the following DANGER Keep in mind that full operator attention and alertness NOTICES before moving or operating the pump or any are required when operating high pressure pumping pump package unit equipment. equipment. Operators should not begin or continue operations when tired, distracted or under the influence Reciprocating pumps are machines capable of of alcohol or any type of prescription or nonprescription producing high fluid pressures and flow rates and are drugs. designed to be used with proper care and caution by trained, experienced operators. TO AVOID The timely replacement of expendable parts and any PERSONAL INJURY, DEATH AND/OR EQUIPMENT other worn or damaged parts can prevent equipment DAMAGE, READ AND THOROUGHLY damage and possible injury. The original parts used in UNDERSTAND THE FOLLOWING DANGER Gardner Denver pumps are designed and tested to NOTICES PLUS THE ENTIRE OPERATING AND exacting standards to provide high quality performance SERVICE MANUAL BEFORE ATTEMPTING TO and durability. Your best insurance in maintaining MOVE OR OPERATE THE PUMP. Contact a Gardner these characteristics is to use genuine Gardner Denver Denver service representative if you are unable to replacement parts. comply with any of the danger notices or procedures described in these documents. A broad range of danger notices are covered on these pages, however, they cannot substitute for training, Closely examine the data plate upon pump delivery to experience and common sense in the safe operation of become thoroughly familiar with the operating limits for high pressure pumping equipment. this pump model. The pump must never be operated at speeds, pressures or horsepower HAMMER LUG FASTENERS exceeding the maximum values shown on the data plate or at speeds below the minimum shown. DANGER Failure to observe the operating limits shown on the data plate could result in personal injury, On pumps or pump package units equipped with death, and/or equipment damage and will void the hammer lug connectors and/or hammer lug valve warranty. Alterations to the pump, or application of covers the following precautions must be observed to the pump outside the data plate limits, must not be avoid personal injury, death and/or equipment damage made without Gardner Denver written approval due to contact with the hammer, hammer bar, broken together with a new data plate, as dangerous operating parts from the hammer, hammer bar or lugs or other conditions could result. objects propelled by hammer blows. When tightening or loosening hammer lug connectors and valve covers, THE DANGER NOTICE AND DATA PLATES operators or maintenance personnel should: PROVIDED ON THE EQUIPMENT MUST NOT BE REMOVED, PAINTED OVER, HIDDEN OR• Inspect the hammer, hammer lugs and hammer bar, if DEFACED. They must be replaced if they become one is used, to insure they are all in good condition. damaged or unreadable. Provisions should be made Replace any of these parts which are cracked, to have the following written danger notices plus the damaged or badly worn. pump operating and service manual readily available to operators and maintenance personnel. In addition, ‚ Wear safety shoes and goggles. copies of all pump system accessory component (e.g. pressure relief valve, pulsation dampener, suction ‚ Alert other personnel to move away from the area. stabilizer, engine, electric motor, etc.) operating and ‚ Check to insure they have safe footing. service manuals should be readily available for operator and maintenance personnel use. Read and ‚ Fully engage the hammer bar, if one is used, to follow all the precautions and instructions contained in prevent it from disengaging violently from the cover these manuals. If any of these documents are lost or as a blow is struck. become illegible they must be replaced immediately. The danger notices plus the operating and service ‚ Wipe their hands and the hammer handle and manuals should be reread periodically by both maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking.

Downloaded from www.Manualslib.com manuals search engine • Carefully swing the hammer to avoid striking EQUIPMENT MOVING AND LIFTING themselves, another person and objects other than the targeted lugs or hammer bar. DANGER • Avoid swinging the hammer above shoulder Heavy equipment including pumps, pump package height. units and components should only be moved or lifted by trained, experienced operators, who are physically VALVE SEAT PULLING and mentally prepared to devote full attention and alertness to the moving and lifting operations. An DANGER operator should be fully aware of the use, capabilities, and condition of both the equipment being moved and The following precautions must be observed by the equipment being used to move it. operators and maintenance personnel to avoid personal injury, death and/or equipment damage from contact with the puller, hammer, wedge or broken DANGER parts from these components when using either a hydraulic or wedge valve seat puller: Failure to follow safe and proper pump, Hydraulic Puller pump package or component lifting or • Wear safety shoes and goggles. moving procedures can lead to • Chain or tie the jack down as it will jump violently personal injury, death and/or when the valve seat disengages from the valve equipment damage from shifting, deck. falling or other unexpected or • Check to insure the pressure applied by the uncontrolled equipment movements. hydraulic pump does not exceed the hydraulic ram maximum pressure rating. Make sure the hoist, lift truck, ropes, slings, spreader, or other lifting equipment you are using is in good Wedge Puller condition and has a rated lifting capacity equal to or • Grind off any mushroomed material from the greater than the weight being lifted. Lifting devices wedge before use. must be checked frequently for condition and • Follow the DANGER notices listed above in the continued conformance to rated load capacity. They hammer lug section, but substitute the term should then be tagged with the inspected capacity wedge for hammer lub an hammer bar. together with the date of inspection. Fully assembled pumps and pump package units are COVERS AND GUARDS heavy and should only be moved using the specified lifting lugs or attachments.

DANGER Many individual components have lifting eyes or lugs which must not be used to lift assemblies, as All pump covers must be securely they are designed to bear the weight of the fastened in proper position at all times component only. when the pump is operating to avoid personal injury or death from moving Before lifting the individual component check to insure the lifting attachment is firmly secured to the parts. In addition, all moving parts on component with undamaged, properly torqued the entire pump package, including but fasteners, sound welds, or other secure attachments. not limited to, the engine or motors, Examine the lifting eyes, lugs, slots, holes or other drive shafts, belts, chains, pulleys, projections to insure they are not cracked, otherwise gears, etc., must be equipped with damaged or badly worn. The repair of existing or addition of new welded lifting eyes, lugs or other guards or covers, which must also be projections should only be performed by experienced, securely fastened in proper position at qualified welders. all times when the equipment is operating. Package units should be lifted with spreaders connected to the lifting attachments normally built into Covers and guards are intended to not only protect the package unit support skid. Packages too large to against personal injury or death, but to also protect lift fully assembled should be separated into smaller the equipment from damage from foreign objects.

Downloaded from www.Manualslib.com manuals search engine loads. For these smaller loads the lifting devices The relief valve should be placed in the flowing should be fastened to the lifting attachments normally discharge line and not at the opposite end of the built into the individual motor, engine, pump or discharge manifold in a dead end connection. The transmission/torque converter, or their separate dead end may become clogged with solid material support skids. carried in the fluid, which could prevent proper relief valve operation. When lifting subassembled components, for example a suction stabilizer attached to suction piping or a discharge pulsation dampener attached to a strainer DANGER cross and piping, use special lifting slings designed to safely support the combined weight of the Never place a shut-off valve or any components. If a crane or hoist is being used to lift other component between the pump large components or assemblies, one or more persons should assist the operator from the ground discharge connection and the pressure with guide lines attached to the equipment being relief valve. moved to properly position it and prevent uncontrolled movement. Make sure the pressure relief valve is installed so any pressurized relief discharge from the valve is directed When you start to lift a pump, package unit, away from possible contact with people or equipment. subassemblies or individual components and you The relief valve must be set to relieve at a pressure observe the equipment is tilting, or appears equal to or below the maximum pressure values unbalanced, lower the equipment and adjust the lifting shown on the pump data plate. However, if a device to eliminate these improper lifting conditions component is used in the discharge system with a before proceeding to move the equipment. lower rated pressure capability than that listed on the pump data plate, the pressure relief valve must be set It is poor practice and dangerous to allow the to relief valve must be set to relieve at a pressure equipment to pass over or close to your body or equal to or below the rated capability of the lowest limbs. Be prepared to move quickly out of danger if rated component. equipment starts to fall, slip or move unexpectedly toward you. Before starting the pump every time, check to insure: PRESSURIZED PUMP SYSTEMS • The pressure relief valve is in good operating condition and has been set to the proper relief DANGER pressure. • Any pipe line used to direct pressurized relief flow to Fluids under high pressure can another location, such as a collecting tank, is not possess sufficient energy to cause blocked. personal injury, death and/or • The discharge system is not blocked and all the discharge line valves are open. equipment damage either through direct contact with escaping fluid Check all fluid end discharge system components streams or by contact with loose including pipe, connections, elbows, threads, objects the pressurized fluid propels. fasteners, hoses, etc., at least once every six months to confirm their structural adequacy. With Operating a pump against a blocked or restricted time, wear, corrosion and fatigue can reduce the discharge line can produce excessive pressures in strength of all components. Magnetic iron and steel the entire discharge system, which can damage or components should be checked with magnetic particle burst discharge system components. or dye penetrate crack detection equipment. Nonmagnetic materials should be checked for cracks with dye penetrants. All metallic components should DANGER also be visually checked during these inspections for signs of corrosion. If a component shows evidence of Never operate a pump without a cracking or loss of material due to corrosion it must be properly sized pressure relief valve replaced with a new part. located in the flowing discharge line Continually monitor suction and discharge hose immediately adjacent to the pump assemblies when the pump is operating for leakage, discharge connection. kinking, abrasion, corrosion or any other signs of wear or damage.

Downloaded from www.Manualslib.com manuals search engine Worn or damaged hose assemblies should be Whenever the pump is operating, continually monitor replaced immediately. At least every six months the entire suction, discharge and pump lubricating examine hose assemblies internally for cut or bulged systems for leaks. Thoroughly investigate the cause tube, obstructions and cleanliness. For segment style for leakage and do not operate the pump until the fittings, be sure that the hose butts up against the cause of the leak has been corrected. Replace any nipple shoulder, the band and retaining ring are parts which are found to be damaged or defective. properly set and tight and the segments are properly When a gasketed joint is disassembled for any spaced. Check for proper gap between nut and reason, discard the used gasket and replace it with a socket or hex and socket. Nuts should swivel freely. new, genuine Gardner Denver gasket before Check the layline of the hose to be sure that the reassembling the joint. assembly is not twisted. Cap the ends of the hose with plastic covers to keep them clean until they are Due to the high working pressures contained by the tested or reinstalled on the pump unit. Following this fluid cylinder, discharge manifold and discharge visual examination, the hose assembly should be piping, welding on these components is not hydrostatically tested, on test stands having adequate recommended. If welding on the discharge system guards to protect the operator, per the hose cannot be avoided, only experienced, qualified manufacturer’s proof test procedure. welders should be used. In addition, the welded part should be hydrostatically proof tested in the shop with Fluid end component inspections should be water or hydraulic fluid to one and one half times performed more frequently than every six months maximum discharge system working pressure, with if pressures above 2,500 PSI are used in the no observable fluid leakage, before the part is discharge system or if corrosive, flammable or reinstalled in the pump system. hot (over 110º F) fluids are being pumped. In summary, high pressure fluid streams can possess Proper stuffing box packing selection is important for sufficient energy to cause personal injury, death safe pump operation. Contact a Gardner Denver and/or equipment damage. These results can occur service representative for assistance in selecting the either through direct contact with the fluid stream or proper packing before beginning operation. by contact with loose objects the fluid stream has Before starting the pump the first time and periodically propelled, if the pump system is improperly used, or if thereafter check the pump, suction and discharge the fluid is misdirected, or allowed to escape from system fastener torques versus the values listed on defective or improperly maintained equipment. page 12 to insure proper tightness. Over and under torquing can damage threaded pipes, connections FLAMMABLE, HOT, COLD OR CORROSIVE FLUID and fasteners, which may lead to component damage PUMPING and/or failure. Replace all components found to be damaged or defective. On pumps equipped with DANGER stuffing boxes, the gland must be engaged by at least three (3) threads to hold the discharge pressure of the Extreme caution must be exercised by pump. trained and experienced operators Block the crankshaft from turning and make certain when flammable, hot, cold or corrosive that all pump drive motor or engine start switches or fluids are being pumped in order to starter controls are clearly tagged with warnings not to avoid personal injury, death and/or start the pump while repair work is in process. equipment damage due to explosion, fire, burn, extreme cold or chemical DANGER attack. Do not attempt to service, repair, or Never operate a pump which is pumping adjust the plunger packing or otherwise hydrocarbons or other flammable, hot, cold, or work on the pump while the unit is corrosive fluids when any part of the pump, suction operating. Shut off the pump drive system or discharge system is leaking. Stop the motor or engine and relieve the fluid pump immediately if any leakage, other than a few drops per minute of packing weepage, is observed. pressure in the pump suction and Keep all flame, sparks, or hot objects away from any discharge systems before any work or part of the pump, suction system, or discharge investigation is performed on the pump system. Shield the pump, suction system and or pump systems. discharge system to prevent any flammable, hot, cold

Downloaded from www.Manualslib.com manuals search engine or corrosive fluid leakage from dripping or spraying on HIGH PRESSURE LIQUID JETTING, BLASTING any components, flame, sparks, hot objects or people. AND CLEANING Inspect the plungers, packing, gaskets and seals for fluid leakage frequently and replace all worn or leaking parts. DANGER Selection of the proper gaskets, seals and stuffing box Extreme caution must be exercised if packing is even more critical when flammable, hot, cold any type of wand, gun, nozzle or any or corrosive fluids are being pumped than when other, other pressure and flow directing inherently less dangerous fluids are used. Contact a device is attached to the pump Gardner Denver service representative for assistance discharge system for use in jetting, in selecting the proper gaskets, seals and packing before beginning operation. blasting, cleaning, etc. This type of equipment must be used with utmost Since some packing weepage into the cradle area is care by trained, experienced operators. inevitable, the drain at the bottom of the cradle must be High pressure fluid streams can either connected to a drain line which conducts the fluid leakage to a collection container located in a protected by direct contact or by propelling loose area. The entire drain system and container must be objects, cause serious personal injury constructed of materials resistant to attack from the or death to the operators and/or other pumped fluid or from explosion or fire of the pumped persons. fluid. Pressure or flow directing devices often receive Heavy duty cradle covers must be securely pressurized flow through flexible hoses, which can fastened in the proper position on the pump at all burst if they are kinked, cut, abraded or are otherwise times when the pump is operating. If the pumped worn, damaged or pressured above their rated fluid releases harmful, explosive or flammable capacity. Protect the hose and connections from vapors the covers must be vented to conduct the damage by people, objects and vehicles. A broken, fumes away from the pump unit to a nonhazardous cut or otherwise burst hose can release pressurized area. fluid which may cause personal injury, death and/or Before beginning pumping operations or starting the equipment damage. pump power source (whether an engine or electric motor) check the atmosphere all around the pumping High pressure fluid from hand held or hand directed site for the presence of flammable or explosive vapors. pressure and flow directing devices may overpower an Do not begin operation and stop ongoing operation if operator’s ability to control or direct the device, which flammable or explosive vapors are detected. Hot could lead to personal injury, death and/or equipment surfaces, sparks, electric current or engine exhaust damage. The operator must brace against the could ignite flammable or explosive vapors. Each backward thrust of a hand held device. In addition, a engine used as a power source on pumping units safety harness or safety net must be used when where flammable or explosive vapors could form working in an area where the operator could be injured should be equipped with an air inlet shut-off. If in a fall. Stand to the side of any tubing or container flammable or explosive vapors are present in the being sprayed to avoid back spray and never operate a pumping site atmosphere, an engine could continue to hand held device above shoulder level. run on these vapors even after the engine fuel line is shut-off if an air inlet shut-off is not used. Never direct the pressurized fluid stream at yourself or any other person, control valves, the pump, pump In addition, on pumping units used where flammable or drive, suction or discharge systems. The pressurized explosive vapors could form, all electric motors used stream can cause serious personal injury or death and as power sources must be of explosion proof can also change valve or control settings which could construction and all electrical components and wiring dangerously increase the delivery pressure to the must meet the current National Electrical Code for pressure and flow directing device. explosive atmospheres. When operating a pressure and flow directing device, These precautions must be taken to avoid possible use only equipment which automatically shuts off flow personal injury, death and/or equipment damage from when an operator releases hand or foot pressure on explosion, fire or burns. the pressurized flow trigger control to prevent injury if the operator is overpowered or becomes disabled.

When operating any type of high pressure liquid All pressure containing devices including wands, jetting, blasting or cleaning devices the operators nozzles, guns, connections, etc., plus all automatic must always wear protective clothing including, but shut-off, pressure and control equipment should be not limited to, a hard hat with full face visor, heavy treated with care. Protect them from damage by duty rain coat and pants, boots with nonskid sole and people, objects and vehicles. Never lay them in dirt, safety toe, rubber gloves with rough grip surface and mud, ice or other loose material which could plug the ear noise protection. fluid opening or interfere with their operation. Never use the wand, nozzle, gun, etc. to pry loose material Full operator attention and alertness are required off items being cleaned. when operating this equipment to avoid personal injury, death and/or equipment damage. The Before starting operation in a cold environment, check operators should take frequent rest breaks and cease to make sure there is no ice in the fluid system and operations when they become tired or distracted. repeat this inspection each time before operation is restarted. Before the equipment is started, the work area must be inspected and properly prepared to avoid personal Before purchasing wands, nozzles, guns, injury, death and/or damage to equipment. Make connections, and hose, etc., manufacturers of these sure the work area is checked for hazardous fumes, components should be contacted for detailed has adequate ventilation for engine exhaust and information on the design and safety features sufficient drainage for released fluid. Check the work incorporated in their products. After careful study of area for electrical equipment, connections, outlets, various manufacturers products, we recommend that fixtures, or lines. If any are present they must be only those wands, nozzles, guns, connections and made water tight and the electrical power to these hose, etc., be considered for purchase that you judge devices must be shut off to avoid electrical shocks to offer the highest quality of design, construction and from fluid contact. The work area should be clearly safety, since these components are among the most marked and roped off to keep unauthorized people critical to the safe operation of high pressure liquid and vehicles from entering. Remove all loose parts, jetting, blasting and cleaning equipment. tools and equipment from the work area before beginning operation. After you have selected and purchased these components, follow the manufacturer’s instructions All pressure containing devices including wands, completely in their use. nozzles, guns, hoses, connections, etc., should be regularly checked for condition. These components should all be tagged with their tested pressure In summary, high pressure jetting, blasting and capabilities together with the date testing was cleaning are inherently dangerous, as the performed. Always be aware of the pressure level pressures and flow rates needed to remove scale, in the system and never connect any equipment clean, etc. are sufficient to cause personal injury, to the system which has a rated or tested death and/or equipment damage resulting from, pressure capability below the system operating but not limited to, any of the conditions described pressure. in the above Danger Notices.

Downloaded from www.Manualslib.com manuals search engine SECTION 2 INSTALLATION & OPERATING INSTRUCTIONS FOR GARDNER DENVER PZ SERIES & PXL SINGLE ACTING POWER PUMPS

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 DANGER 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 If the drive is not to be removed, it is the yard for sometime and as a consequence dirt may recommended that the air line to the have entered the crankcase. Parts may have been clutch be disconnected to prevent robbed from the pump during storage and not accidental starting of the pump. replaced. All nuts and screws should be tightened.

Be sure all valves in the discharge line are open. No LOCATION - Pump should be set level and solidly valve should be installed between the pump and supported. The drive should be accurately aligned. pressure relief valve in discharge line. Pump should be placed as close to the slush pit as possible to keep the suction line short and direct. To prevent excessive wear on the fluid pistons and Locate pump as low as possible to maintain a packing when starting, remove a suction valve cover minimum suction lift to the centrifugal charging pump plate on each side of the fluid end and prime the pump. which is used because of the high speed of this type of Pump should be started slowly, if possible, and should mud pump. be operated for several hours with practically no When the pump skid or master skid is to be bolted or discharge pressure. Check oil level as it may be welded to a platform or deck in the field, it is necessary necessary to add a small quantity of oil to compensate that the following “Final Shimming Procedure” be for that adhering to the walls of the crankcase the followed. moving parts. The pump may then gradually be brought up to full speed and full working pressure. Final Shimming Procedure - After the pump skid or Watch for undue heating or abnormal noise in the master skid has been bolted or welded to a stationary working parts. Check all joints in the suction line to be platform or deck, proceed as follows: sure there are no air leaks. a. Remove the cap screws used to secure the pump frame to its skid. DANGER b. At each foot where a space exists between foot and skid, place a dial indicator on the frame foot When working on any pump, be certain and skid as shown in FIGURE 1. Set dial to ZERO. there is no fluid pressure on either the suction or discharge side. Pressure on c. Place shims between frame foot and skid where the fluid end might move the pump and space exists so the dial indicator shows the frame cause damage or injury to personnel. It has been raised approximately .005 to .010 is recommended that all suction valve inches (.126 to .254 mm). covers be removed to avoid fluid d. Securely tighten the frame to skid cap screws. If pressure building up against the pistons the proper number of shims were used, the dial or plungers. indicator should return to within +/-.003 inches (.076 mm) of zero. If not, repeat the procedure changing number of shims used.

Downloaded from www.Manualslib.com manuals search engine DANGER NOTE: Never install a shutoff valve in the line This is only when the skid is secured between the pressure relief valve and to a STATIONARY foundation. the pump discharge manifold. DIAL FRAME SUPPORT INDICATOR FOOT If more than one pump is used, a pressure release valve should be furnished for each pump. A hand- operated 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 SHIM from discharge line in starting. It is also used to relieve pressure in starting more than one pump in parallel. A75738 SURGE CHAMBER - A surge chamber is essential. FIGURE 1 – FINAL SHIMMING One MUST be used for protection to surface equipment and to reduce pulsations when pumping SUCTION LINE - Suction pipe or hose to centrifugal gaseous mud. A nitrogen-charged pressure-bag type charging pump should be a minimum of 12 inches surge chamber is recommended. The surge chamber (304.8 mm) diameter and as short as possible. Always must be kept properly charged, as instructed by the use eccentric reducers when reducing suction pipe manufacturer. size. Suction line should slope up toward the charging pump at uniform grade to prevent air pockets being STARTING A NEW PUMP - It is recommended that formed. Suction line must be absolutely tight as any air the drive be arranged to turn the pump in the direction leaking into the line will reduce the capacity of the indicated by arrow shown on the sectional view in this pump and cause a hydraulic hammer or knock. If it is book, on outline prints, and indicated on pump frame. necessary to have bends in the suction line they This book provides for crosshead load to be carried on should have long radius sweeps and be kept to a the lower side. This means better lubrication and quiet minimum in quantity. 10 PSI - 40 PSI suction required. operation. Lube oil pumps are not automatice Suction line should be supported near centrifugal reversing. charging pump to keep strain from breaking the casing If the PZ series or the PXL pumps are to be run in at suction flange. reverse direction, refer to “Lube Oil Pump”. Pumps are shipped from the factory without oil in the At least one section of hose in the suction line is crankcase. The hood should be removed and the desirable to isolate pulsations or vibration. Total power end examined and cleaned if necessary. The suction line should be as short as installation pump may have been in storage or in the yard for conditions permit. THIS IS IMPORTANT. some time, and as a consequence, dirt may have entered the crankcase. Drain all water accumulated in A suction strainer is recommended for the suction line the bottom of the crankcase. Fill crankcase with oil of of every pump. It must be checked frequently and proper grade to the proper level. Quantity shown on cleaned whenever necessary. A commercial strainer lubrication data plate indicates the approximate oil may be installed in suction line ahead of the pump. 2 requirements. All nuts and cap screws should be It is recommended that a 50 PSI (3.515 kg/cm ) gauge checked for tightness. with a needle valve for protection be installed in the It is recommended that the fluid end of the pump be suction line at the discharge of the centrifugal charging primed to prevent excessive wear on the fluid pistons pump. This gauge will indicate if pump is charging or if and liners when starting. PRIMING IS IMPORTANT! suction valves are not working properly. IT LUBRICATES THE PISTONS IN THE LINERS. RELIEF VALVES - The pump should be protected Pump should be started slowly but not run below half from excess discharge pressure by a 3 inch (76.2 mm) of rated speed. Recheck oil level as it may be relief valve. This valve should be installed in a vertical necessary to add a small quantity of oil to crankcase position in a tee mounted directly onto either end of and the moving parts. The pump may then be discharge manifold or discharge cross. 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.

LUBRICATION - All power end working parts are • Failure to follow these lubrication requirements will lubricated by the oil in the crankcase. Check oil level void the warranty. frequently. Selection of oil is to be taken from the recommendations given in FIGURE 2 and on the pump • Some operating conditions and/or oil brands data plate. Local conditions and practice may also produce excessive oil foaming, even when the influence the selection. Essential additives are foam specified GL-5 oils containing antifoaming and oxidation inhibitors. Oil is to be added as required additives are used. Oil foaming can cause pump to maintain oil level near the top of the oil level damage, as oil bubbles will not lubricate moving indicator on the side of the frame. parts properly. If significant oil foaming occurs, contact Gardner Denver Marketing or Service, • Oil viscosity must not exceed 7000 SSU at start-up (217) 222-5400, for the current factory and must be between 1500 SSU and 200 SSU recommended defoamant to be added to the while operating, regardless of the oil temperature or lubricating oil. grade used. A crankcase heater and/or an oil heat exchanger may be needed to meet these • Oil must have antiwear, antifoaming, noncorrosive requirements. and rust inhibiting additives.

Oil is constantly circulated through a renewable LUBRICATION SCHEDULE element filter and then through a heat exchanger, Frequency Type Procedure when one is used, by means of a rotary pump driven Daily *A.P.I. Type GL-5 Check oil level with pump from the main gear. Oil is discharged into an elevated Lubricant running. oil feed trough, from which it is conducted to jackshaft and main bearings. Oil also flows from the trough to Daily 50% Water Plus 50% Check fluid level in piston lubricate the connecting rod bearings. Water Soluble Oil wash tank. Operating temperatures of the oil should be kept below 1000 Hours *A.P.I. Type GL-5 Change oil and clean o o Lubricant inside of frame. Change 200 F (93.3 C) to reduce oxidation. oil filter element. FIGURE 3 – LUBRICATION SCHEDULE

Downloaded from www.Manualslib.com manuals search engine On units equipped with a heat exchanger, oil flows through the oil filter before going through the heat OIL CAPACITIES exchanger. Pumps Without Heat Exchanger Model Cast Frame Fabricated Frame PZG 60 Gal. (227.1 Liters) None PZH 60 Gal. (227.1 Liters) 85 Gal. (321.8 Liters) PZJ 70 Gal. (264.9 Liters) 105 Gal. (397.4 Liters) PZK 85 Gal. (321.8 Liters) 100 Gal. (378.5 Liters) PZL 85 Gal. (321.8 Liters) 100 Gal. (378.5 Liters) PXL 85 Gal. (321.8 Liters) None

Pumps With Heat Exchanger Model Cast Frame Fabricated Frame PZG 41 Gal. (155.2 Liters) None PZH 41 Gal. (155.2 Liters) 65 Gal. (321.8 Liters) PZJ 50 Gal. (189.3 Liters) 85 Gal. (397.4 Liters) PZK 85 Gal. (321.8 Liters) None PZL 85 Gal. (321.8 Liters) None PXL 85 Gal. (321.8 Liters) None FIGURE 5 – OIL FILTER MOUNTING

Time between oil changes depends upon local and/or HEAT EXCHANGER (Optional Equipment) - For PZ operating conditions. Under normal circumstances, if series & PXL pumps a bronze heat exchanger can be the crankcase is kept clean, it should not be necessary provided to keep crankcase oil temperature at 160° F to change the oil more than once in 1000 hours of (71.1° C) by means of an automatic water control operation. Many operators change oil after each well valve. This valve has a sensing probe in the crankcase drilled. Oil should be changed if found to be dirty or oil, and it monitors water to the heat exchanger to contaminated with mud or water, as the oil lubricated maintain oil temperature within close limits. roller bearings will be damaged by contamination. An Water must be drained from the heat exchanger during oil change is comparatively inexpensive, as the freezing weather. Ruptured water tubes will admit approximate crankcase capacities are shown above. water into the oil, with resulting damage to working parts of the pump. In order to assure proper lubrication, the PZG, PZH & PZJ pumps should not be run under 10 RPM for more Cooling water can be drained from the heat exchanger than a few minutes at a time without providing by removing water connections and blowing additional lubrication from an extra external oil pump. compressed air into upper opening. Water will then The PZK, PZL & PXL pumps should not be run under flow from the lower opening. Air is necessary, as water 40 RPM. will not otherwise drain due to small size of tubes, capillary attraction, and the horizontal position of the The oils normally used in large mud pumps are quite heat exchanger mounting. viscous at lower temperatures. When starting cold, the Water should not be admitted to the heat exchanger as pump should be started slowly and brought up to long as oil temperatures do not exceed 160° F(71.1° operating speed slowly. This practice will assure C). A dial thermometer is standard equipment on all PZ proper lubrication of all working parts before pump is series and PXL pumps. fully loaded. Salt water can be used for cooling. Zinc anode plugs OIL FILTER - A replaceable element oil filter is located are provided for corrosion protection. These plugs are inside the pump crankcase. Filter mounting flange is on to be replaced when they have been corroded away. oil is changed or every 1000 hours of operation. Filter element is protected from excessive internal oil DIRECTION OF ROTATION - The PZ series & PXL pressure by a relief valve between it and the oil pump. pumps MUST be driven in the direction as shown by arrow on sectional view, outline drawing and on pump Filter element should be replaced