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OPERATING AND SERVICE MANUAL

1. 33 WV aa EE ee cade beet eee nuts chee 35 Page iii Charging Pump Requirement 14 Covers and Guards Danger Notice 2 Crankshaft sse 11 Crosshead 11 Daily Routine Maintenance 18 DANGER NOTICES SECTION 1 1 DESIGN DESCRIPTION AND SPECIFICATIONS SECTION 2 9 Equipment Moving and Lifting 2 Flammable Hot cold or Corrosive Fluid Pumping Danger Notice 5 Fluid Cylinder Installation 21 Fluid End 12 Fluid End 20 Fluid End 20 Gear Train 11 General Requirements and Safety Rules 20 General 13 High Pressure Liquid Jetting Blasting and Cleaning Danger Notice 6 Hydraulic Puller Danger Notice 2 Introduction 9 Lube Pump Suction Piping Sizing and 15 Lube System 15 Monthly Routine Maintenance Schedule 18 Performance Rating HD 2250 13 Periodic Routing Maintenance Schedule
2. Warning devices to monitor lube oil pressure and temperatures are highly recommended The triplex pump operates at very high rod loads and pressures and malfunction of the lube system may result in serious damage occurring in very short time Therefore early warning devices are essential to successful operation and should be set according to the following operating limits NOTICE Maximum lube system pressure should be set at 125 psi max relief valve setting Minimum lube oil operating pressure is 40 psi With hot oil Minimum lube pump flow is 30 gpm Approximate lube pump design flow should be 40 gpm with relief valve controlling flow Maximum lube system vacuum at lube pump inlet 8 Hg or 4 psi or 0 28 bar FIGURE 3 1 Indicates API GL5 oil grades recommended for use in the pump power end and the speed reducer lube system crankcase operating temperature ranges and minimum startup temperatures for each listed grade of oil for various ambient temperature ranges INLET OR AWARNING SUMP GAUGE OIL TEMPERATURE sF oC CRANKCASE API GL 5 OIL REQUIREMENTS MAX ALLOWABLE TEMP ii RANGE FOR FACH OIL TYPE SHOWN BY COMBINED 70 77 OILS FOR OILS FOR S SHADED AND UNSHADED 60 71 LOW TO MEDIUM VERTICAL ARROW LENGTHS 50 m MEDIUM TO HIGH FOR PUMPS RUNNING AMBIENT AMBIENT UNDER LOAD AT STABILIZED B TEMPE TENES OPERATIN
3. 7 8 9 340 Fluid End Suction Manifold 7 8 9 340 Discharge Flange to Fluid Cylinder Nuts 1 8 511 Conn Rod Bearing Housing Cap Screws 1 8 475 Bull Gear Retaining Screws Gr 8 1 1 4 7 1350 Stay Rods into Frame 1 3 4 8 1000 Fluid End to Stay Rods Nuts 1 3 4 8 2000 Crosshead Thrust Bearing Retainer to Grosshead e eee 1 2 13 58 heal 5 8 11 116 Plunger Clamp Bolts 5 8 11 75 Page 34 Product Warranty BE 13 02 2003 Copyright 2003 Gardner Denver Inc GENERAL PROVISIONS AND LIMITATIONS Gardner Denver the Company warrants to each original retail purchaser Purchaser of its new products assemblies or parts from the Company or its authorized distributors that such products are at the time of delivery to the Purchaser made with good material and workmanship No warranty is made with respect to 1 Any product which has been repaired or altered in such a way in the Company s judgment as to affect the product adversely 2 Any product which has in the Company s judgment been subject to negligence accident or improper storage improper installation operation or application Examples over pressure sand outs cavitation corrosion erosion or degradation 3 Any produ
4. 18 Plunger Packing Lubrication 16 Plunger Packing Lubrication Recommendation Chart 19 Plungers and Packing Replacement 21 INDEX Page iv Power End sese 10 Power End Internal Lube Sytem 12 Power End Lubrication System 15 Power End 23 Preparation after Shipping and Storage 14 PREPARATION OPERATION AND MAINTENANCE SECTION 3 14 Pressurized Pump Systems Danger Notice 3 Pump 10 Pump Mounting Instructions 14 Quarterly Routine Maintenance Schedule 18 Rebuilding 33 REBUILDING DATA RUNNING CLEARANCES AND TORQUES 6 33 Repair Parts Ordering Instructions Running Clearances Actual 33 SERVICE PROCEDURES SECTION 4 20 Startup and New Pump Run In Procedure 16 Torque 34 TROUBLE SHOOTING SECTION 5 27 Valves and Seats Replacement 22 Valve Seat Pulling Danger Notice 2 Warrenty cf iiie n o eR 35 Wedge Puller Danger Notice 2 LIST OF ILLUSTRATIONS F
5. Air entering charging pump 1 See recommended system layout in manual See Low Suction Pressure problem Install suction stabilizer and pulsation damper Repair and recharge or replace Reduce pump speed Increase NPSH Increase supply line size Decrease supply line length Use weaker spring Allow more settling time in supply tank Reduce pump speed Repair suction line Tighten or replace shaft packing or seal Repair and recharge stabilizer Use a suction stabilizer on each pump Separate lines may also be needed Install supports or hangers See Cavitation Fluid Knock or Hammer problem Use an oil heat exchanger with a circulating pump Use recommended oil Reduce pump speed and or pressure Check and adjust clearance Replace parts as required PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Knock In Power End Excessive Valve Noise Oil Leakage From Stop Head 1 Improper main bearing clearance 2 Incorrect pump rotation 3 Loose plunger coupling 4 Loose bearing housings covers o Worn crosshead pin o Worn crosshead pin bushing 7 Worn connecting rod to journal bearing 8 Worn crankshaft 9 Worn crosshead 10 Worn main bearing 11 Valve noise transmitted to power end 12 Cavitation noise transmitted to or causing shock loading in power end 1 P
6. Description and Specifications describe the pump design list the pump specifications and present drawings depicting the pump external views and all essential cross sectional drawings L 89 91 i 4 X 91Xe MOUNTING HOLES il oro loo Gr 3 e Il g HIS TEX MURS Ld f A 65 62 s doolo o i CG J 15 50 8 5 n g 26 81 on m 32 00 ld et UE ae 9 SS EA cer _1 NPT LUBE INLET 18 88 26 25 EITHER SIDE H 48 50 50 31 22 38 CG 1 4 FPT DRAIN ON PUMP CENTERLINE 59 55 FIGURE 2 1 HD 2250 PUMP Page 9 Section 3 Pump Preparation Operation and Maintenance addresses the issues of preparing the pump for operation after shipping or storage the lubrication system design and specifications the new pump run in procedures and the periodic routine maintenance schedule The recommended oils viscosity data and crankcase oil temperature requirements also presented in this section PUMP DESIGN The HD 2250 is a horizontal single acting 2250 h
7. Geoquip 4747 South 83 East Avenue 2121 West 44 Street 7533 Kathy Lane Tulsa Oklahoma 74145 Odessa Tx 79768 Ft Worth Texas 76126 Phone 918 664 1151 Phone 432 366 5433 Phone 817 249 6400 800 738 8099 800 368 1134 800 824 0271 Fax 918 664 6225 Fax 432 363 9940 Fax 817 249 6401 INSTRUCTIONS FOR ORDERING REPAIR PARTS When ordering parts specify Pump MODEL and SERIAL NUMBER see nameplate on unit The Serial Number is also stamped on top of the cylinder end of the frame cradle area All orders for Parts should be placed with the Tulsa or Ft Worth facility Where NOT specified quantity of parts required per pump or unit is one 1 where more than one is required per unit quantity is indicated in parenthesis SPECIFY EXACTLY THE NUMBER OF PARTS REQUIRED Pagei FOREWORD Gardner Denver pumps are the result of advanced engineering and skilled manufacturing To be assured of receiving maximum service from this pump the owner must exercise care in its operation and maintenance This book is written to give the operator and maintenance personnel essential information for day to day operation maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimal downtime DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored AN WARNING
8. Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored TN caution Caution is used to indicate the presence of a hazard which will or can causq minor personal injury or property damage if the warning is ignored NOTICE Notice is used to notify people of installation operation or maintenance information which is important but not hazard related Page ii TABLE OF CONTENTS Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and Support Dre M eese et i Instructions For Ordering Repair Parts ssssssssssssseseseeenenen nennen nennen i FOF WOM a ii io d iv List t rm ge fte Lee t fei i lea Section 1 Danger NotICes cane e e rie ttf a c vein oes 1 Section 2 Design Description and 9 Section Preparation Operation and Maintenance sess 14 Section 4 Service Procedures aonaran ferite cn e iri P d dee M RED REC 20 Section 5 Trouble Shooting esssssssssssssses essen enne ninth nennen ennt nnns entree ns 27 Section 6 Rebuilding Data Recommended Running Clearances
9. and safety toe rubber gloves with rough grip surface and ear noise protection Full operator attention and alertness are required when operating this equipment to Page 7 avoid personal injury death and or equipment damage The operators should take frequent rest breaks and cease operations when they become tired or distracted Before the equipment is started the work area must be inspected and properly prepared to avoid personal injury death and or damage to equipment Make sure the work area is checked for hazardous fumes has adequate ventilation for engine exhaust and sufficient drainage for released fluid Check the work area for electrical equipment connections outlets fixtures or lines If any are present they must be made water tight and the electrical power to these devices must be shut off to avoid electrical shocks from fluid contact The work area should be clearly marked and roped off to keep unauthorized people and vehicles from entering Remove all loose parts tools and equipment from the work area before beginning operation All pressure containing devices including wands nozzles guns hoses connections etc should be regularly checked for condition These components should all be tagged with their tested pressure capabilities together with the date testing was performed Always be aware of the pressure level in the system and never connect any equipment to the system which has a rated or tested
10. correct plunger See recommended system layout and correct error Prime pump Remove pocket from line Clean out line Remove the obstruction Replace valve assembly Remove the obstruction See Cavitation Fluid Knock or Hammer problem Replace plungers packing and or fluid end seals Recalibrate or replace gauge s Raise fluid supply level Install charging pump Increase charging pump speed or size Remove restrictions from suction line Recalibrate or replace gauge s PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Cavitation Fluid Knock or Hammer Suction or Discharge Line Vibration High Crankcase Oil Temperature 1 2 10 11 12 13 1 Improper suction system layout Low suction pressure Suction stabilizer and pulsation damper not used Defective stabilizer or damper High fluid temperature or viscosity High fluid vapor pressure High acceleration head Suction valve spring too stiff with low NPSH Air Gas in pumped fluid Air entering suction line Air entering or charge gas escaping from suction stabilizer Multiple pumps operating in phase Line s not supported Pump cavitating High ambient temperature Improper type grade oil used Pump overloaded Improper clearance in main or rod bearings crossheads or bushings Page 28
11. covered on these pages however they cannot substitute for training experience and common sense in the safe operation of high pressure pumping equipment HAMMER LUG FASTENERS DANGER On pumps equipped with hammer lug unions and or hammer lug valve covers the following precautions must be observed to avoid personal injury death and or equipment damage due to contact with the hammer broken parts from the hammer lugs or other objects propelled by hammer blows When tightening or loosening hammer lug unions and valve covers operators or maintenance personnel should e Inspect the hammer and hammer lugs to insure they are all in good condition Replace any of these parts which are cracked damaged or badly worn e Wear safety shoes and safety glasses e Alert other personnel to move away from the area e Check to insure they have safe footing e Fully engage the hammer bar if one is used to prevent it from disengaging violently from the cover as a blow is struck Page 1 Wipe their hands and the hammer handle and maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking Carefully swing the hammer to avoid striking themselves another person and objects other than the targeted lugs or hammer bar above Avoid swinging the hammer shoulder height VALVE SEAT PULLING A The following precautions must be observed by operators and maintenance personnel to
12. fluid 3 Check seal stuffing box End groove and sealing surface 4 Corrosion due to wrong 4 Determine and install correct stuffing box material stuffing box for pumped fluid 5 Stuffing box bore worn 5 Replace stuffing box Pumped Fluid In 1 Worn damaged or corroded 1 Replace extension rod Crankcase extension rod 2 Worn oil stop head seal 2 Replace seal 3 Stuffing box leakage 3 See Stuffing Box Leakage problem Short Valve Life 1 Abrasives in pumped fluid 1 Filter pumped product Use severe duty valves with insert 2 Valve not sealing 2 Broken valve spring replace Worn valve guide replace Worn valve seat replace 3 Pump cavitating 3 See Cavitation Fluid Knock or Hammer problem 4 Corrosion 4 Treat pumped fluid Page 30 Use different materials for valves seats Install sacrificial anodes in suction manifold PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Short Plunger Packing Life Catastrophic Failures Broken Shafts Bent Rods etc 1 Abrasives in pumped fluid 2 Excessive plunger packing friction 3 Metal parts or particles wearing plunger 4 Wrong plunger packing for pumping conditions 5 Wrong size packing 6 Improper packing installation 7 Excessive crosshead wear 8 Pump cavitating 1 Pump overloaded 2 Start up against closed discharge valve 3 Main bearing failure 4 Plunger striking valve or valve parts 5 Plunger striking cyli
13. on power requirements HD 2250 PUMP SPECIFICATIONS U S SYSTEMS Rated Hydraulic Horsepower 2250 hp Stroke Length 8 0 Inches Maximum rod Load 237 500 Pounds Gear Ratio 6 3531 Overall Length 90 inches Overall Width 66 inches Overall Height 51 inches Weight system dry 12 650 Pounds HD 2250 PERFORMANCE RATING U S Plunger Gallons 100 RPM 150 RPM 200 RPM 330 RPM Size Per Inches Rev GPM _ PSI GPM PSI GPM PSI GPM PSI 7 5 4 59 459 5379 688 5044 918 3783 1514 2293 7 0 4 00 400 6174 599 5790 799 4343 1319 2632 6 75 3 72 372 6640 557 6227 743 4670 1226 2830 6 50 3 45 345 7161 517 6715 689 5036 1137 3052 6 00 2 94 294 8404 440 7881 587 5911 969 3582 5 75 2 70 270 9151 404 8581 539 6436 890 3900 5 50 2 47 247 10002 370 9379 493 7034 814 4263 5 0 2 04 204 12102 306 11348 408 8511 673 5158 4 50 1 65 165 14941 248 14010 330 10508 545 6368 4 00 1 31 130 18909 196 17732 261 13299 431 8060 3 75 1 15 115 21515 172 20175 229 15131 378 9170 Brake Horsepower 1600 2250 2250 2250 Based on 90 Mechanical Efficiency and 10096 Volumetric Efficiency Page 13 SECTION 3 PREPARATION OPERATION AND MAINTENANCE DANGER Read and understand clearly all safety rules and precautions before attempting to operate the pump This section deals with pump preparation after shipping and storage of the pump user built lubrication
14. 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 AN Fluids under DANGER 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 produce excessive pressures in the entire discharge system which can damage burst discharge system components DANGER Never operate a pump without a properly sized pressure relief valve or working overpressure shutdown in the discharge line immediately adjacent to the pump discharge The relief valve should be placed in the flowing discharge line and not at the opposite end of the discharge manifold in a dead end con
15. strength of all components Magnetic iron and steel components should be checked with magnetic particle or dye penetrant crack detection equipment Nonmagnetic materials should be checked for cracks with dye penetrants All metallic components should also be visually checked during these inspections for signs of corrosion If a component shows evidence of cracking or loss of material due to corrosion it must be replaced with a new part Continually monitor suction and discharge hose assemblies when the pump is operating for leakage kinking abrasion corrosion or any other signs of wear or damage Worn or damaged hose assemblies should be replaced immediately At least every six months examine hose assemblies internally for cut or bulged tube obstructions and cleanliness For segment style fittings be sure that the hose butts up against the nipple shoulder the band and retaining ring are properly set and tight and the segments are properly spaced Check for proper gap between nut and socket or hex and socket Nuts should swivel freely Check the layline of the hose to be sure that the assembly is not twisted Cap the ends of the hose with plastic covers to keep them clean until they are tested or reinstalled on the pump unit Following this visual examination the hose assembly should be hydrostatically tested on test stands having adequate guards to protect the operator per the hose manufacturer s proof test procedure Fluid
16. system and its specifications pump break in procedures recommended oils allowable crankcase operating temperatures viscosity conversion tables and routine maintenance schedule PREPARATION AFTER SHIPPING AND STORAGE All pumps are shipped dry and therefore must be flushed with light weight oil before operating The flushing must be performed regardless of method or duration of the shipment or type of container the pump was shipped in Pumps are not prepared for storage and should be put in service as soon as possible If for any reason the pump has to be put into storage after prior use the following procedure should be followed 1 Clean and flush the fluid end with a rust preventative 2 Plug all discharge and suction openings 3 Drain oil from the power end and the gear reduction unit 4 Flush the power end with a rust preventative before flushing make sure that the rust preventative will not clog the oil passages 5 Remove the breather and either plug or tape the opening Page 14 6 Coat the gear reducer input shaft and all exposed bare metal with a heavy rust preventive 7 Plug drain holes at the bottom of the pump frame at the rear of the pump and the gear reducer drain 8 Plug the lube inlet in the lube manifold 9 Store the pump inside in a warm dry place 10 Ifthe pump is shipped ocean cargo it must be crated in a water tight contain er placed below the deck to prevent rustin
17. the lube pump suction inlet is less the 8 Hg or 4 psi or 0 28 bar Check whether the lube system pressure reading is at least 100 psi or 7 0 bar Temporary pressure gages should be also checked at this time to make sure that all components of the lube system are working properly Check to see that oil flow back to the reservoir is normal There should be no accumulation in the power end Start the plunger lube system and check whether it is adjusted properly Run at low speed to work out any trapped air in the fluid cylinder with the charge pump operating Run the pump at 80 90 strokes per minute and 20 of its maximum pressure rating for 30 minutes Se Power End Internal Lube System page 12 During this time observe the suction vacuum gage reading oil pressure and temperature and check for leaks Run the pump at 80 90 strokes per minute at the following loads 40 of full rated load 30 min 60 of full rated load 30 min 80 of full rated load 30 min 100 of full rated load 30 min 13 14 15 16 17 18 19 20 Page 17 During the operation observe the oil pressure and temperature and inlet suction vacuum gage reading and entire system for proper operation If the triplex pump is equipped with a transmission run the pump for 30 minutes in each gear in the higher gear ranges pulling full horsepower in each gear Observe the oil pressures temperatures and lube oil su
18. this warranty LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedules caused by but not limited to location or inaccessibility of the equipment or labor provided by unauthorized service personnel is not provided for by this warranty All costs of transportation of product or parts claimed not to be as warranted and of repaired or replacement parts to or from such service facility shall be borne by the Purchaser The Company may require the return of any part claimed not to be as warranted to one of its facilities as designated by the Company transportation prepaid by the Purchaser to establish a claim under this warranty Replacement parts provided under the terms of this warranty are warranted for the remainder of the Warranty Period of the product upon which installed to the same extent as if such parts were original components The Company may request a root cause analysis be performed in order to identify if a request for warranty claim meets the requirements of this warranty DISCLAIMER Except as to title the foregoing warranty is the sole and exclusive warranty of the Company The Company hereby extends
19. to change without notice Copyright O 2001 Gardner Denver Inc Litho in U S A
20. you have selected and purchased these components follow the manufacturer s instructions completely in their use summary high pressure jetting blasting and cleaning are inherently dangerous as the pressures and flow rates needed to remove scale clean etc are sufficient to cause personal injury death and or equipment damage resulting from but not limited to any of the conditions described in the above Danger Notices Page 8 SECTION 2 DESIGN DESCRIPTION AND SPECIFICATIONS INTRODUCTION The Gardner Denver HD 2250 is a multi purpose pump for various applications such as oil well servicing water blasting industrial use etc The pump was designed using modern analytical engineering methods and techniques for stress analysis of structural components gears and journal bearings The gear drive was calculated in accordance with the most recent standards procedures computer software developed by American Gear Manufactures Association The HD 2250 has a proven track record as a reliable trouble free pump The Issue of personnel safety is the most important topic covered in this manual Therefore in the beginning of this manual the user is introduced to dangers inherent in the operation of a high pressure pump To avoid accidents and injuries all safety rules listed in this section and also all other applicable safety rules and regulations must be carefully observed The sections on Pump Design
21. CLEARANCES ACTUAL New in Maximum Allowable Wear Limit in Connecting Rod Bearing to Crankshaft 0055 0105 018 Crosshead Knuckle to Thrust Bearing 0005 0020 006 Wrist Pin to 003 006 020 Main Bearing Installed Clearance 002 004 019 Main Bearing Bench 011 013 028 033 Crosshead to Guide sssssssssssseeeee 017 025 045 Crankshaft Endplay sene 005 015 030 Pinion Float prior to gear 1 4 to 3 8 Feeler gauge clearances 001 inch less than actual values Page 33 RECOMMENDED TORQUES FOR HD 2250 PUMP MAINTENANCE TORQUES FOOT POUNDS i DESCRIPTION FASTENER WITH LOCTITE WITH ANTISEIZE Gear Covers MISC schien nt ni 3 8 16 16 Main Bearing retainer plate screws Gr 8 1 2 13 58 Plunger Clamp 1 2 13 58 Pinion Bearing Housing 3 4 10 160 Extension Rod to Crosshead 3 1 4 8 1200 Conn Rod to Bearing Housing Lock Nuts
22. E GARDN E R DENVE Re 300THD996 Revision A January 2005 HD 2250 WELL SERVICING PUMP OPERATING AND SERVICE MANUAL Gardner ver ECN 1024137 HD 2250 WELL SERVICING PUMP MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Gardner Denver genuine pump parts are manufactured to design tolerances and are developed for optimum dependability Design and material innovations are the result of years of experience with hundreds of different pump applications Reliability in materials and quality assurance is incorporated in our genuine replacement parts Your authorized Gardner Denver Sales Office offers all the backup you ll need The Fort Worth Manufacturing Facility maintains a large inventory of genuine parts Gardner Denver supports your needs with these services 1 Trained parts specialists to assist you in selecting the correct replacement parts 2 Repair and maintenance kits designed with the necessary parts to simplify servicing your pump Authorized service technicians are factory trained and skilled in pump maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver distributor refer to the yellow pages of your phone directory or contact Factory Tulsa Service Center Odessa Service Center Ft Worth Gardner Denver Well Servicing Pumps Chaparral
23. G TEMP SHADED ARROW RANGE 120 49 ADVISED FOR LONGEST 10 43 00 38 85W 140 MINIMUM NO LOAD COLD 90 32 MINERAL pow 140 START UP OIL TEMP 80 27 SYNTHETIC SHOWN BY HORIZONTAL ARROWS FOR EACH OIL 70 21 80w 90 TYPE E i phis AFTER COLD START UP q DO NOT LOAD PUMP 40 4 UNTIL OIL REACHES MIN 30 1 oom OPERATING TEMP SHOWN AT BOTTOM OF SHADED VERTICAL ARROWS OIL USED MUST CONTAIN ANTI FOAMING NON CORROSIVE AND RUST INHIBITING ADDITIVES OIL VISCOSITY MUST NOT EXCEED 7000 SSU AT COLD START UP AND MUST BE BETWEEN 1500 AND 200 550 WHILE OPERATING REGARDLESS OF OIL TEMPERATURE OR GRADE USED A CRANKCASE HEATER AND OR HEAT EXCHANGER MAY BE NEEDED TO MEET THESE REQUIREMENTS FAILURE TO FOLLOW THESE LUBRICATION REQUIREMENTS VOIDS THE WARRANTY FIGURE 3 1 Lubricant Recommendations PLUNGER PACKING LUBRICATION The fluid end plungers are lubricated from a separate lubrication pump through the stuffing box The lubrication pump hosing and check valve to the stuffing box is not provided with the unit See Plunger Packing Lubrication Recommendation Chart page 19 for a list of lubricants recommended for plunger packing lubrication STARTUP AND NEW PUMP RUN IN PROCEDURES A centrifugal charge pump will be required to charge the fluid end suction manifold The charge pump should be sized according to the volume to be pumped by the triplex pump so that there is no less than 50 psi charge
24. LD OR CORROSIVE FLUID PUMPING P A DANGER Extreme caution must be exercised by trained and experienced operators when flammable hot cold corrosive fluids are being pumped to avoid personal injury death an or equipment damage due to explosion fire 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 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 a drain located below the
25. OWN No statement representation agreement or understanding oral or written made by any agent distributor representative or employee of the Company which is not contained in this Warranty will be binding upon the Company unless made in writing and executed by an officer of the Company Page 36 This warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed not to have been as warranted Any action for breach of this warranty must be commenced within one year after the date upon which the cause of action occurred Any adjustment made pursuant to this warranty shall not be construed as an admission by the Company that any product was not as warranted WARRANTY REQUESTS Products to be returned for warranty analysis shall be approved for return in writing by the Company prior to shipment All requests for product return shall be submitted by email Facsimile or letter to Warranty Department c o Gardner Denver Petroleum Pumps 4747 South 83 East Avenue Tulsa Oklahoma 74145 Email CCR QAR gardnerdenver com Facsimile 918 664 6225 BE 13 R 02 2003 Copyright 2003 Gardner Denver Inc Page 37 Gardner Denver For additional information contact your local representative or Gardner Denver Inc 4747 South 83 East Avenue Tulsa OK 74145 PH 918 664 1151 800 637 8099 FAX 918 664 6225 www gardnerdenver com Specifications subject
26. Run In Procedure page 16 Daily Routine Maintenance Tasks 1 Check the oil level in the lube oil reservoir 2 Periodically monitor lube oil operating pressure temperature The maximum oil operting temperature depends on a particular grade of oil used in the pump lube system See FIGURE 3 1 Page 16 3 Check the lube pump suction inlet vacuum A vacuum gage reading higher than 8 Hg or 4 psi or 0 28 bar indicates that the suction strainer and or oil filter element are clogged The strainer must be cleaned and the oil filter element replaced as necessary as soon as the pump can be shut down for a short period of time to perform these tasks 4 Listen for any abnormal noise or rough operation which may indicate the need for fluid end maintenance such as changing valves or valve seats Due to very high pressures in the triplex pump fluid end worn valves and seats should be changed as soon as possible to prevent washing them out with the pumped fluid 5 Check the plunger packing lubrication pump for proper operation Insure packing nut is tightened sufficiently into fluid cylinder Recheck tightness after extended continuous operation Monthly 100 hour Routine Maintenance Tasks 1 Clean the strainer and replace the oil filter element 2 Check the entire lube system for leaks and eliminate them 3 Check all fluid end expendables such as valves packings and valve seats and replace them as necessa
27. ac 150 EP Rockdrill 49 17 78 Rockdrill 100 Rockdrill 32 Arox EP 46 Arox 150 Almo 525 Almo 527 Almo 529 Almo 532 Rockdrill 150 Rockdrill 600 EP 500 Summer or EP 300 Winter Torcula Oil 32 Torcula Oil 100 Torcula Oil 150 Torcula Oil 320 Rockdrill 500 Light Rockarill 1000 Heavy Rockdrill Oil XL Rockdrill Oil XM Rockdrill Oil XH Marok 150 STEAM CYLINDER OILS HIGH TEMPERATURE PUMPED FLUIDS Source Amoco Arco Conoco Exxon Gulf Oil Chevron Mobil Oil Co Pacer Oil Phillips Petroleum Shell Oil Co Sun Oil Co Texaco Oil Co Type Amoco Cylinder Oil 460 Modco Cylinder Oil 125 175 Inca Cylinder Oil Cylesstic TK 460 or TK 1000 Senate 375 Compound Security 460 Non Compound Mobil Cylinder Oil 600W Com Cyl Oil Hector Cylinder Oil Valvata J 460 Occident Gear Oil 7 X Gear Oil 8 C Pinnacle Cylinder Oil Page 19 Pour Point Maximum 20 F 0 0 15 10 5 0 5 30 F 35 F 20 F 35 F 20 F 20 F 10 F 0 10 0 10 50 F 20 F 15 F 10 F 5 F 5 40 0 10 SECTION 4 SERVICE PROCEDURES This section describes various assembly and disassembly procedures necessary for pump servicing or parts replacement The General Requirements and Safety Rules section is a reminder for the maintenance personnel of the critical importance of safety rules and precaut
28. and materials of the new parts installed Weld repaired fluid ends and weld repaired components are not warranted Expendable fluid end parts including but not limited to valves valve parts packing liners and pistons are not covered by this warranty due to variable abrasive nature of material pumped crm PRESERVATION ASSEMBLIES DESTINED FOR STORAGE In order for warranty acceptance any pump assembly not immediately installed or destined to be in storage or in transit for extended periods of time must be prepared for storage as defined in the Company s Long Term Storage Procedure This includes but is not limited to Drain and thoroughly clean inside power end crankcase Spray rust inhibiting oil on all bearing machined and inside surfaces of the power end Induce clean gear oil into any circulating pump filter heat exchanger and piping Remove valves seats and plungers from the fluid end Thoroughly clean and dry these parts and all internal surfaces Coat all cylinder bores valve covers and reusable expendable parts with rust preventative Flush all water and contaminants from pump tanks hoses and spray nozzles Spray all components with a rust inhibiting oil Page 35 Rotate pump every 30 days to insure bearings are oiled At the expense of the Purchaser any product properly preserved must be inspected by an authorized agent of the Company prior to the Company granting any extended warranty beyond that stated in
29. atures a hardened and ground thrust area for extended wear capabilities Oil is fed under pressure to the knuckle bearing through drilled passageways to further extend the durability of this assembly The knuckle bearing features lubrication grooves designed to feed oil to all the wearing surfaces It is made of a high grade bearing material with a babbit coating for improved break in characteristics The wrist pin which is made of heat treated ground high strength alloy steel serves only to return the crosshead assembly It bears none of the thrust load generated at maximum pressure operation FIGURE 2 3 HD 2250 POWER END SECTION B B GEAR TRAIN The gear train features precision ground heat treated helical cut gears on each end of the crankshaft They are driven by gears integrally machined into the alloy steel pinion shaft These gears are precision timed to each other which eliminates time consuming inexact manual timing of these gears CRANKSHAFT The crankshaft is made of high strength alloy steel that has been precision machined and heat treated for fatigue resistance and long wear It has been drilled with lubrication passageways to provide oil for all the connecting rod journal bearings as well as the crosshead assembly Page 11 POWER END INTERNAL LUBE SYSTEM FIGURE 2 2 page 10 and FIGURE 2 3 page 11 There is a single inlet for the lube oil coming from the lube oil pump After entering
30. 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 DANGER hydraulic or wedge valve seat puller Operators or maintenance personnel should Hydraulic Seat Puller e Wear safety shoes and glasses Chain or tie the jack down as it will jump violently when the valve seat disengages from the valve deck Check to insure the pressure applied by the hydraulic pump does not exceed the hydraulic ram maximum pressure rating Wedge Puller e Grind off any mushroomed material from the wedge before use Inspect the hammer and wedge to insure they are in good condition Replace any of those parts which are cracked damaged or badly worn Wear safety shoes and goggles Page 2 Check to insure they have safe footing Fully engage the wedge to prevent it from disengaging violently from the cover as a blow is struck Wipe their hands and the hammer handle and maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking Carefully swing the hammer to avoid striking themselves another person and objects other than the targeted wedge Avoid swinging the hammer above shoulder height DANGER Personal injury death and or equipment damage can result from contact with moving parts All moving parts must be equipped with covers and guards All covers and guards must be securely
31. 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 non hazardous area Before beginning pumping operations or starting the pump power source whether an engine 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 Page 6 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 electr
32. cial conn rod wrench remove bottom 3 lock nuts 5 Remove three nuts on top of conn rod 6 Screw 34 10 all thread into conn rod bearing housing as a handle 7 While another person is moving the 34 all thread in an up and down motion pull the crosshead assembly forward out of the front of the pump 8 Remove the Pony Rod from the crosshead assembly by using a spanner wrench to rotate the rod counterclockwise 9 To remove the wrist pin remove one of the wrist pin snap rings 10 Remove the wrist pin through the side of the crosshead The crosshead may now be removed from the conn rod Page 23 11 12 wr 7 FIGURE 4 5 Crosshead Assembly the fasteners from the thrust bearing X retainer retainer to access the Remove crosshead Remove the thrust bearing Examine the thrust bearing and the mating surface of the connecting rod These must be free from nicks burrs and wear before they can be reused Conn Rod Bearing Housings 1 To remove the conn rod bearing housing remove the four 4 cap screws retaining the bearing cap Remove the cap noting that two dowel pins PILOT the halves together Do not damage dowel pins CAUTION Both halves are heavy Cap half of bearing has locator pins Remove action half bearing with prying Rod half of bearing may be tapped on one edge with a rubber hammer or wo
33. ct which has not been operated or maintained in accordance with the recommendations of the Company 4 Components or accessories manufactured warranted and serviced by others 5 Anyreconditioned or prior owned product Claims for items described in 4 above should be submitted directly to the manufacturer WARRANTY PERIOD The Company s obligation under this warranty is limited to repairing or at its option replacing during normal business hours at an authorized service facility of the Company any part or assembly which in the Company s judgment proved to have unsatisfactory material or workmanship within the applicable Warranty Period as follows Except for the products or components listed below and subject to the limitations and restrictions set forth in the Disclaimer section set forth below the Warranty Period for all products is 1 250 hours of operation or three 3 months after start up not to exceed 120 days after delivery to Purchaser whichever occurs first The exceptions are as follows 1 Power end is warranted for twelve 12 months from date of start up or eighteen 18 months from date of delivery to the Purchaser whichever occurs first 2 Forged steel fluid cylinders are warranted for materials and workmanship for 6 months from the date of installation or 18 months from the date of delivery to the purchaser which ever occurs first 3 Repairs are warranted for 90 days from the date of delivery for the workmanship
34. ction vacuum closely Shut the pump down and let it cool thoroughly before starting normal operation of the pump During the shutdown change the oil filter elements and clean the suction strainer Change the lube oil and clean the reservoir to get rid of metal particles and any other wear products now present in lube oil system Change filter elements and clean the strainer every 10 15 hours until it becomes apparent that the wear in process is finished Change the lube oil again replace the filter elements and clean the strainer after 80 100 hours of pump operation Folow the routine maintenance schedule described in the next chapter after completion of the wear in period PERIODIC ROUTINE MAINTENACE SCHEDULE Performance of the periodic routine maintenance tasks described this section will ensure long economical and trouble free operation of this pump It is highly recommended that the customer set up a maintenance program during the run in period The periodic maintenance data should be recorded and kept with other pump documents The following recommendations based on previous experience should serve as a guideline for establishing a good maintenance program The periodic maintenance schedule is divided into daily monthly and quarterly tasks to be performed by the user after the pump has gone through 100 hours of wear in For the tasks performed during the wear in period see Startup and New Pump
35. customers for each particular application The lubrication system is very critical to the triplex pump performance and therefore should be professionally designed in accordance with sound engineering practices developed for similar systems known otherwise as hydraulic power units or HPU The following discussion will re emphasize some of the good practices used in designing similar systems in the past and comment the system s critical components Lube System Pump A positive displacement pump must be used Gear type pumps have demonstrated reliable performance for similar applications in the past The pump should have the largest suction port available for the selected pump size to minimize losses in the suction piping Lube Pump Suction Piping Sizing and Requirements In the past failure to meet these requirements has lead to pump damage because of restricted oil flow in the lube pump inlet Therefore the following guidelines developed as a result of long experience should be adhered to closely 1 The oil flow velocity through the suc tion piping should not exceed 2 ft sec or 0 6 m sec At maximum operating speed the vacuum reading at the lube pump inlet must be no more than 8 hg or 4 psi or 0 28 bar Page 15 The suction strainer should be sized for oil flow three 3 times larger than the actual flow passing through the strainer The suction pipe should be kept as short as possible and free of bends
36. ease the packing bore in the fluid end 10 Install the packing in the packing bore with the packing lips toward the front of the fluid end See FIGURE 4 2 A PACKING NUT PLUNGER 2020PE224 Ref Drawing FIGURE 4 2 Packing Assembly Page 21 FLUID END STUFFING BOX 11 Install and hand tighten the packing nut to align the packing in the borehole 12 Loosen the packing nut to allow for installation of the plunger 13 Insert the plunger through the suction cover hole into the packing It may be necessary to bump the plunger through the packing with a slide hammer 14 Tighten the packing nut 15 Inspect the clamp surfaces of the plunger and the extension rod for cleanliness 16 Install the clamp and tighten the clamp screws to the specified torque on page 34 17 Tighten the packing nut again 18 Replace the O ring and back up rings on the suction cover and apply grease or O ring lube 19 Install the suction cover and tighten the suction cover retainer nut 20 Make sure that the plunger lube line is in place before restarting the pump Valve and Seats Replacement This procedure can be performed with the fluid cylinder on the pump Before starting make sure that special tools required for this procedure are available For part number of the tools see Parts Manual AN WARNING Never try to remove or cut a valve seat with a torch Severe damage to the fluid end may occur 1 Re
37. end component inspections should be performed more frequently than every six months if pressures above 2500 psi are used in the discharge system or if corrosive abrasive flammable or hot over 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 DANGER Do not attempt to service repair or adjust the plunger packing or other wise work on the pump while the unit is operating Shut off the pump drive engine and relieve the fluid pressure in the suction and discharge systems before any work or investigation is performed on the pump or pump systems Block the crankshaft from turning and make certain that all pump drive motor or engine start switches or starter controls are clearly tagged with warnings not to start the pump while repair work i
38. er Denver service representative if you are unable to comply with any of the danger notices or procedures described in these documents Closely examine the pump performance data upon pump delivery to become thoroughly familiar with the operating limits for this pump model The pump must never be operated at speeds pressures or horsepower exceeding the maximum values or at speeds below the minimum Failure to observe the operating limits could result in personal injury death and or equipment damage and will void the warranty Alterations to the pump or application of the pump outside the limits must not be made without Gardner Denver written approval together with a new set of performance data as dangerous operating conditions could result Keep in mind that full operator attention and alertness are required when operating high pressure pumping equipment Operators should not begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription drugs The timely replacement of expendable parts and any other worn or damaged parts can prevent equipment damage and possible injury The original parts used in Gardner Denver pumps are designed and tested to exacting standards to provide high quality performance and durability Your best insurance in maintaining these characteristics is to use genuine Gardner Denver replacement parts A broad range of danger notices are
39. g and salt water contamination PUMP MOUNTING INSTRUCTIONS Because of the lightweight low stiffness nature of these pumps it is easy to twist or distort the frame during installations Therefore it is necessary to follow this procedure to shim the feet of these pumps This requires 4 grade 8 1 00 diameter cap screws of the appropriate length lockwashers nuts if required and shims if required 1 Setthe pump in its location 2 Using a feeler gauge check under the feet at all four boltdown locations Select the proper number and thickness of shims to fill the gap under the high foot Note it is better to use shims up to 005 too thick than to leave any gap under the foot With shims in place install bolts in all four locations CHARGING PUMP REQUIREMENT A centrifugal pump will be required to prime the fluid end suction The centrifugal pump should be sized to generate a minimum of 50 PSI at maximum flow Increased pressure is required for pumping higher volumes heavy sand concentrations and other special fluids and propping agents To reduce shock and cavitation which can cause severe damage a suction dampener should be used POWER END LUBRICATION SYSTEM Due to variety of applications and drive arrangements the power end lubrication pump and applicable auxiliary hydraulic equipment are not furnished with the triplex pump Therefore the pump lubrication system is designed and built by individual
40. ic motors used as power sources must be of explosion proof construction and all electrical components and wiring must meet the current National Electrical Code for explosive atmospheres These precautions must be taken to avoid possible personal injury death and or equipment damage from explosion fire or burns HIGH PRESSURE LIQUID JETTING BLASTING AND CLEANING AN Extreme caution must be exercised if any type of wand gun nozzle or any other pressure and flow directing device is attached to the pump discharge system for use in jetting DANGER blasting cleaning etc This type of equipment must be used by trained experienced operators with the utmost care High pressure fluid streams can either by direct contact or by propelling loose objects cause serious personal injury or death to operators and or other persons Pressure or flow directing devices often receive pressurized flow through flexible hoses which can burst if they are kinked cut abraded or are otherwise worn damaged or pressured above their rated capacity Protect the hose and connections from damage by people objects and vehicles A broken cut or otherwise burst hose can release pressurized fluid which may cause personal injury death and or equipment damage 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 pers
41. igure Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 3 1 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Description Page HB 2250 PUmp ee eee hd re da ep dla tates ere 9 HD 2250 Power End Section A A sse 10 HD 2250 Power End Section B B 11 BIOL e etta ttd a OS E 12 Power End Lubricant 16 Fluid End Stay Rods and Heavy Hex Nuts 21 Packing Assembly delete die tte PR RR ten 21 Valve Cage Spring 22 Gunsight Spring Retainer sssssssssseeeee enne 22 Crosshead Assembly sesssssssssssssseseeeeeeeneen nnne nnne 24 Page v SECTION 1 DANGER NOTICES DANGER Read and understand the following DANGER NOTICES before moving or operating the pump or any pump package unit equipment Reciprocating pumps are machines capable of producing high fluid pressures and flow rates and are designed to be used with proper care and caution by trained experienced operators TO AVOID PERSONAL INJURY DEATH AND OR EQUIPMENT DAMAGE READ AND THOROUGHLY UNDERSTAND THE FOLLOWING DANGER NOTICES PLUS THE ENTIRE OPERATING AND SERVICE MANUAL BEFORE ATTEMPTING TO MOVE OR OPERATE THE PUMP Contact a Gardn
42. ing safety precautions must be observed 1 Shift the pump transmission into the neutral gear 2 Shut off the pump engine and remove the key from the ignition to prevent starting the engine inadvertently The power end service procedures deal first with major assemblies namely crosshead connecting rod crankshaft knuckle joints and gear and pinion sets and then describe how to access all individual parts Oil Stop Head Seal Retainer and Gear Covers FIGURE 2 2 and FIGURE 2 3 1 Remove any plunger cradle chamber covers or guards 2 Disconnect the input drive line and remove the input drive flange from the pinion shaft 3 Remove the plunger clamps and slide the plungers forward 4 Remove the Oil Stop Head retainer cap screws and remove the Head 5 Remove roto seals and oil hoses from gear covers 6 Remove input seal housing from left hand cover 7 Remove the cap screws in gear covers Covers can now be removed Crosshead Assembly FIGURE 4 4 1 Remove the fluid end following the procedure described in Fluid End Removal and Installation page 20 2 Remove the oil stop head seal retainer and off drive gear cover following the procedure described in Oil Stop Head Seal Retainer and Gear Covers page 23 3 Remove the rear inspection cover from power frame inspect the gaskets 4 Rotate crankshaft until rod bearing housing is in highest position Using Socket and impact wrench or spe
43. ions while working on the pump Notes on dangers and notices specifically related to service procedures are repeated and placed in this section also The pump consists of two major modules 1 the fluid end and 2 the combination power end and gear reduction unit See Section 3 The description of service procedures follows the modular concept Due to many expendable parts fluid end servicing is rather common in the field and is therefore presented in the very beginning followed by power end and gear reduction unit servicing procedures General Requirements and Safety Rules DANGER Before any attempt to work on pumps is made all safety rules and precautions described in this manual must be read and clearly understood DANGER Only qualified and specially trained personnel should be allowed to work on this pump DANGER Proper capacity hoist and lifting devices should be used while working on pump FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly and proceeds to the removal and replacement of expendable parts such as valves valve seats and packing Fluid End Removal 1 Disconnect suction and discharge lines plunger oiler lines and also any accessories such as stroke counters pressure gages etc from the fluid cylinder 2 Open the hinged cradle cover on the top of the crosshead housing if equipped and disc
44. move the discharge cover retainer nut with the proper hex wrench 2 Remove the discharge cover with a slide hammer type puller 3 Remove the suction cover retainer nut with the proper hex wrench 4 Remove the suction cover with a slide hammer type puller 5 Remove the suction valve spring retainer The suction valve spring and valve can now be removed by hand SAA LLL LA FIGURE 4 4 Gunsight Spring Retainer 6 Remove the suction valve seat or discharge valve seat with a seat puller and a seat puller jack These tools are available from Gardner Denver 7 Clean the valve seat deck thoroughly 8 Snap the replacement valve seat into the taper by hand to fit tightly 9 Place the winged valve on the top of the valve seat Page 22 10 Bump the seat into the taper 2 3 times with a heavy bar to make the fit tight 11 Reinstall the valve spring and suction valve spring retainer 12 Reinstall the suction valve cover and retainer nut 13 Reinstall the discharge valve spring cover and retainer nut 14 Run the pump at 8096 to 10096 of the maximum discharge pressure until the seats into the fluid end tapered holes Listen for 6 distinct loud pops POWER END SERVICE A DANGER Before attempting to service the power end of the pump the follow
45. nder 6 Frozen fluid in cylinder 7 Lube oil pump failure Page 31 1 Consult Gardner Denver Customer Service for plunger packing recommendation Filter pumped fluid Lubricate with rock drill oil Do not overtighten adjust able packing Use Gardner Denver plungers Check stuffing box alignment Check gland alignment Check plunger alignment Check packing for foreign particles Replace lantern ring Consult Gardner Denver Customer Service Install correct size packing Check installation procedure and install correctly Replace crosshead See Cavitation Fluid Knock or Hammer problem Reduce pump speed and or pressure Insure valve is open before starting Repair or replace Check valve condition and installation procedure Check plunger for proper length Do not start pump when pumped fluid is below freezing temperature Replace oil pump PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Catastrophic Failures Broken Shafts Bent Rods etc continued Stud Failures 8 Low oil level in sump 9 Contaminated oil in sump 10 Cavitation shock loading 1 Catastrophic failures 2 Improper nut torquing 3 Stud bending due to uneven nut seating 4 Corrosive attack by pumped fluid 5 Studs damaged before installation 6 Low strength studs Page 32 1 Check oil level frequently and add
46. nection The dead end may become clogged with solid material carried in the fluid which could prevent proper relief valve operation A DANGER Never place a shut off valve or any other component between the pump discharge connection and the pressure relief valve Make sure the pressure relief valve is installed so any pressurized relief discharge from the valve is directed away from possible contact with people or equipment The relief valve must be set to relieve at a pressure equal to or below the maximum pressure values shown on the pump data plate However if a component is used in the discharge system with a lower rated pressure capability than that listed on the pump data plate the pressure relief valve must be set to relieve at a pressure equal to or below the rated capability of the lowest rated component Before starting the pump every time check to insure e The pressure relief valve is in good operating condition and has been set to the proper relief pressure Page 4 Any pipe line used to direct pressurized relief flow to another location such as a collecting tank is not blocked The discharge system is not blocked and all the discharge line valves are open Check all fluid end discharge system components including pipes elbows connections threads fasteners hoses etc at least once every six months to confirm their structural adequacy With time wear corrosion and fatigue can reduce the
47. nnect a sling and overhead hoist to one gear Pull gear off and lay on side for safekeeping Remove second gear Remove capscrews retaining pinion bearing housings Using jack screw holes remove one bearing housing Pinion and other housing may now be removed with the aid of a lift Crankshaft Assembly 1 Remove the pump from the trailer and move it to a service area The pump service area must have overhead lift capability Power end must be level Remove the fluid end as described in Fluid End Removal and Installation page 20 Remove the oil stop head seal retainer and gear covers as described in Oil Stop Head Seal Retainer and Gear Covers page 23 Remove the crosshead assemblies as described in Crosshead Assembly page 23 Remove the connecting rods described in Crosshead Assembly as Remove the bull gears as described in Gear Reduction Unit on page 24 For best results a special crankshaft handling tool should be fabricated to fit one of the 7 000 dia Crankshaft bosses This L shaped lifting tool should come up and over the top of the pump out to the centerline for easy balanced lifting of the crankshaft This tool must be capable of lifting the crankshaft in a horizontal position The crankshaft is now free to move 10 11 12 13 Install the special crankshaft lifting tool and balance the crank with an overhead lift Thread the crank
48. oden handle to remove Cap and Rod half must stay together as a unit for re assembly Re assembled unit must be free to move on crankshaft Crosshead Guide and Stay Rods 1 The crosshead guides or slide should be replaced if excessively worn or damaged See CLEARANCES pg 33 If the crosshead guides must be replaced it is recommended that it be done either by Gardner Denver or a qualified machine shop The stay rods are threaded into the power frame They can be easily replaced by unscrewing and re torquing new rods See Torque on pg 34 Check all stay rods for proper torque plus check for broken or cracked threads The stay rods need to be torqued to the values shown on page 34 when they are installed in the power end Gear Reduction Unit NOTICE This assembly is a timed gear set and should be changed as a gear set Proper timing can be done through the use of offset keys Page 24 Disconnect the input pinion shaft from the transmission or drive shaft Disconnect the gear cover lube hoses and remove the roto seals from the crankshaft Remove the input drive flange from the pinion shaft Remove the input pinion seal and pinion seal housing from the gear cover Remove the cap screws retaining the gear covers and remove the covers 6 T 10 Cut the safety wire if used and remove the four 4 screws Remove the set screws on the square keys pull keys with a puller Co
49. oil as required 9 Check oil condition frequently 10 See Cavitation Fluid Knock or Hammer problem See Catastrophic Failures problem 2 Check torque specifications and torque to correct values 3 Check nut seat surface for flatness Rework or replace as required 4 Treat fluid or use corrosion resistant studs 5 Check condition before installation and replace if necessary 6 Use Gardner Denver studs SECTION 6 REBUILDING DATA RUNNING CLEARANCES AND TORQUES REBUILDING DATA FOR HD 2250 PUMP PUMP STROKE 8 Inches Crankshaft Throw 7 251 7 249 Crankshaft Shaft Diameter at Main Bearing 16 002 16 001 Distance Between Main Bearing Centers 12 00 Bore in Frame for Main 19 750 19 752 Bore in Frame for Pinion Bearing Housing 11 001 11 003 Connecting Rod Centers sss 12 00 Connecting Rod Bearing Bore Assembled in Bearing 7 254 7 259 Crosshead Guide Bore sse 9 877 9 880 Crossh ead OD saan ea eee e eg de er roe e ecd 9 860 9 855 Wristpini Diar o cii de ie 2 500 2 499 Wristpin Bushing Bore sse 2 503 2 505 RECOMMENDED RUNNING
50. onal injury death and or equipment damage The operator must brace against the backward thrust of a hand held device In addition a safety harness or safety net must be used when working in an area where the operator could be injured in a fall Stand to the side of any tubing or container being sprayed to avoid back spray and never operate a hand held device above shoulder level Never direct the pressurized fluid stream at yourself or any other person control valves the pump pump drive suction or discharge systems The pressurized stream can cause serious personal injury or death and can also change valve or control settings which could dangerously increase the delivery pressure to the pressure and flow directing device When operating a pressure and flow directing device use only equipment which automatically shuts off flow when an operator releases hand or foot pressure on the pressurized flow trigger control to prevent injury if the operator is overpowered or becomes disabled Check to insure this automatic shut off equipment is operating properly before every use and never circumvent the automatic shut off for any reason or by any means when operating the equipment When operating any type of high pressure liquid jetting blasting or cleaning devices the operators must always wear protective clothing including but not limited to a hard hat with full face visor heavy duty rain coat and pants boots with nonskid sole
51. onnect the plungers from the pony rods by removing the pony rod clamps 3 Slide the plungers into the fluid cylinder as far as possible 4 Connect a hoist to the fluid end and tighten the lines until they are snug only Make sure that hoisting slings are not too tight because that may cause a strain on the fluid end and cause injury or damage when removing from the pump frame 5 Remove the twelve 12 1 3 4 tie rod nuts from the fluid end flange using a hydraulic tensioning tool or hammer wrench A hydraulic or manual torque wrench is recommended for proper re installation 6 Pull the fluid end assembly horizontally forward straight away from the power end until it is completely clear of the tie rods 7 Move the fluid end to the service area for changing valves or other service Page 20 NOTICE The procedure for fluid cylinder installation is presented separately due to the special and critical nature of the connection between the power end and the fluid end Fluid Cylinder Installation 1 Check all twelve stay rods for thread damage or cracks If replacement is required refer to the torque specifications page 34 This connection is critical 2 Thoroughly clean the ends of the stay rods Apply grease or never seize to the threads 3 Positions the fluid end on the stay rods and slide the fluid end onto the stay rods until it bottoms out on the stay rod shoulders 4 Install the two ou
52. orsepower triplex pump It has an 8 stroke and various plunger sizes from 3 75 diameter through 7 5 diameter The weight of this pump will vary slightly due to the various accessories but will not exceed 12 650 pounds Materials used in the power end have been selected to provide long life and meet the rigorous demands required for H Hi m Al 2 well servicing applications All sizes of plunger fluid ends are interchangeable on the power end POWER END The power end is available in 6 353 1 gear ratio only This is a dry sump pump designed for pressure lubrication fed through various hoses and drilled passageways to the main bearings rod bearings knuckle joints etc Because of the various drive arrangements for powering these pumps the lubrication pump itself is not built in It must be sized and mounted to suit each particular application NOTICE The direction of rotation must be such that the top side of the crankshaft is moving toward the fluid end SS FIGURE 2 2 HD 2250 POWER END CROSS SECTION Page 10 2 KEAN KK CROSSHEAD ASSEMBLY The crosshead assembly features a one piece high strength connecting rod This connecting rod is a much more durable design than the old multiple piece connecting rods commonly used by other companies This one piece design was first developed by Gardner Denver It fe
53. other manufactures warranty or guaranties if any given to Company by such manufacturer but only to the extent the Company is able to enforce such warranty or guaranties The Company has not authorized any party to make any representation or warranty other than as expressly set forthherein SELLER HEREBY DISCLAIMS AND EXCLUDES ANY OTHER EXPRESS IMPLIED OR STATUTORY WARRANTIES ARISING BY OPERATION OF LAW OR OTHERWISE INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE COMPANY MAKES NO WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER EXPRESS IMPLIED OR STATUTORY OF LAW OR OTHERWISE ON ANY EQUIPMENT COMPONENT PARTS OR ACCESSORIES SOLD HEREUNDER WHICH ARE NOT MANUFACTURED BY COMPANY NOTWITHSTANDING ANYTHING HEREIN TO THE CONTRARY THE FOREGOING WARRANTY SHALL BE THE SOLE AND EXCLUSIVE REMEDY AVAILABLE TO THE PURCHASER UNDER NO CIRCUMSTANCES WHETHER IN CONTRACT TORT OR OTHERWISE SHALL THE COMPANY S TOTAL LIABILITY ARISING IN CONNECTION WITH ANY PURCHASE ORDER EXCEED THE AMOUNT OF ANY SALES OR OTHER PROCEEDS RECEIVED PURSUANT THERETO IN ADDITION UNDER NO CIRCUMSTANCES WHETHER IN CONTRACT TORT OR OTHERWISE SHALL THE COMPANY BE LIABLE FOR LIQUIDATED SPECIAL INDIRECT INCIDENTAL EXEMPLARY OR CONSEQUENTIAL DAMAGES EXPENSES OR COSTS INCLUDING WITHOUT LIMITATION LOST PROFITS OR FACILITY DOWNTIME HOWEVER CAUSED AND EVEN IF THE POTENTIAL OF SUCH DAMAGES WAS DISCLOSED AND OR KN
54. positioned at all times when the unit is in operation COVER AND GUARDS Covers and guards are intended to not only protect against personal injury or death but to also protect the equipment from foreign object damage EQUIPMENT MOVING AND LIFTING A Heavy equipment including pumps pump packages and components should only be moved or lifted by trained experienced operators who are physically and mentally DANGER prepared to devote full attention alertness to the moving lifting operations An operator should be fully aware of the use capability and condition of both the equipment being moved and the equipment being used to move it DANGER Failure to follow safe and proper pump pump package or component lifting or moving procedures can lead to personal injury death and or equipment damage from shifting falling other unexpected uncontrolled equipment movements Make sure the hoist lift truck ropes slings spreader bar or other lifting equipment you are using is in good condition and has a rated lifting capacity equal to or greater than the weight being lifted Lifting devices must be checked frequently for condition and continued conformance to rated load capacity They should then be tagged with the rated capacity together with the date of inspection Fully assembled pumps and pump packages are heavy and should only be moved using the specified lifting lugs or attachment
55. pressure capability below the system operating pressure The equipment must be shut down and the system pressure released before changing or disconnecting wands nozzles guns hoses connections or any other pressurized system components All pressure containing devices including wands nozzles guns connections etc plus all automatic shut off pressure and control equipment should be treated with care Protect them from damage by people objects and vehicles Never lay them in dirt mud ice or other loose material which could plug the fluid opening or interfere with their operation Never use the wand nozzle gun etc to pry loose material off items being cleaned Before starting operation in 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 hoses etc manufacturers of these components should be contacted for detailed information on the design and safety features incorporated in their products After careful study of various manufacturers products we recommend that only 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
56. ry 4 Check the power end plunger seals and replace them as necessary Quarterly 300 hour Routine Maintenance Tasks 1 Change the lube oil and clean the oil reservoir thoroughly 2 Clean the lube system strainer and replace the oil filter elements 3 Re tighten the critical bolt joints following torque specifications given in Section 6 4 Add grease to any exposed bare metal to prevent corrosion 5 Clean or replace the breather cap filter element 6 Check all pressure temperature and vacuum gages for proper operation and replace as necessary 7 Check all lube system warning and alarm devices for proper operation and replace if found defective 8 Check supply of on hand expendables such as packings valves and seats maintenance items such as seals O rings oil and breather filter elements and also maintenance tools Order to replenish supplies as necessary The periodic maintenance procedures are very simple and can be performed in a short period of time Page 18 PLUNGER PACKING LUBRICATION RECOMMENDATION CHART ROCK DRILL LUBRICANTS NORMAL CONDITIONS Source Amoco Arco Chevron Oil U S A Conoco Gulf Oil Chevron Exxon Mobil Cil Co Pacer Oil Phillips Petroleum Shell Oil Co Sun Oil Co Texaco Oil Co Union Oil of Ca Type Amoco Rock Drill Oil Light Amoco Rock Drill Oil Medium Air Drill 147 Arco Trueslide 150 Vistac 68 Vistac 100 Vist
57. s 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 Page 3 as fully assembled should be separated into smaller loads For these smaller loads the lifting devices should be fastened to the lifting attachments normally built into the individual motor engine pump or transmission torque converter or their separate support skids When lifting subassembled components for example a suction stabilizer attached to suction piping or a discharge pulsation damper attached to a strainer cross and piping use special lifting slings designed to safely support the combined weight of the components If a crane or hoist is being used to lift large components or assemblies one or more persons
58. s in process Whenever the pump is operating continually monitor the entire suction discharge and pump lubricating systems for leaks Thoroughly investigate the cause for Page 5 leakage and do not operate the pump until the cause of the leak has been corrected Replace any parts which are found to be damaged or defective When a gasketed joint is disassembled for any reason discard the used gasket and replace it with a new genuine Gardner Denver gasket before reassembling the joint Due to the high working pressures contained by the fluid end discharge manifold and discharge piping welding on these components is not recommended f 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 improperly maintained equipment FLAMMABLE HOT CO
59. shaft through the bearing races until all of the bearings are free Carefully place the crankshaft on a clean piece of cardboard clean plywood or clean rug Cover the crankshaft and bearings with plastic to prevent contamination of the bearings If the bearings are to be replaced remove the outer race from the frame by removing the lock and retainer rings If the crankshaft main bearings are to be replaced all bearing retainers must be removed from the crankshaft The crankshaft should be held in a vertical position and the bearings rapidly heated and allowed to drop off to the floor Crankshaft Replacement 1 Before installing the crankshaft check to be sure that all oil passages are clear Install the main bearing inner race assembly and retainer rings starting from the center mains outward The main bearing inner race assembly is readily installed by utilizing a hot oil bath Retainer rings must be brazed at their ends in order to make secure in groove NOTICE Avoid brazing the ring to the crankshaft Page 25 5 Install the outer races and retainer rings in the power frame A light uniform pressure is required to install WARNING the race The retainer rings are secured in grooves by installing locks When reassembling the crankshaft 6 The crankshaft can installed assembly make sure to follow these through either end of the power end steps 1 Pack the outer races in dry ice 7 Re
60. ter most Heavy Hex Nuts and hand tighten Now it is safe to remove the lift and sling Install and hand tighten the remaining heavy hex nuts 5 Using a hydraulic tensioning tool or torque wrench torque all hex nuts to the torque specifications shown on page 34 Use a Oylinder Head sequence These nuts must be kept tight Under torqued nuts will lead to thread fatigue failure of the stay rods 6 Re install the plunger clamps piping connections and auxiliary equipment FIGURE 4 1 HD 2250 Fluid End Stay Rods and Hvy Hex Nuts Plunger and Packing Replacement This service procedure can be performed with the fluid cylinder in place on the pump and consists of the following steps 1 Remove the suction cover retainer nut with the appropriate male hex wrench 2 Remove the suction cover with a threaded slide hammer type puller 3 f equipped open the hinged cover on the top of the crosshead housing to get access to the plunger extension rod area 4 Remove both cap screws holding the extension rod clamp then remove clamp 5 Loosen the packing nut to free the plunger from packing pressure 6 Remove the plunger through the suction cover opening 7 Remove the packing nut packing and spacers 8 Inspect the plunger the packing the rod wiper and the packing nut for excessive wear nicks burrs or any other defects Replace expendable parts as necessary 9 Clean and gr
61. the inlet the lube oil flow is divided into two lines 1 Through external hoses and rotating unions the lubrication oil enters the crankshaft where it is distributed to the connecting rod journal bearings and the knuckle bearing and wrist pin bearings 2 Through the lubrication manifold oil is distributed to the main bearings and the outside of the crosshead There is one drain hole on the bottom of the power frame User plumbing will direct drain oil flow back into the lube sump FLUID END FIGURE 2 4 The conventional valve over valve configuration offers field proven valve and spring performance Improvements in the fluid end life come from 1 New sophisticated methods of metallurgical control which enable us to obtain steel with very consistent chemical components and mechanical properties This results in extended cylinder life 2 Internal edges and corners are hand radiused blended and polished for Page 12 improved resistance to fatigue cracking Extreme pressure autofrettage for long cylinder life and resistance to cracking at the bore intersection areas e FLUID END FIGURE 2 4 GENERAL SPECIFICATIONS This section presents the pump basic specifications U S amp Metric The first set of specifications deals with the pump s power rod load plunger stroke and overall dimensions Two other tables present allowable pressures and flows for various plunger sizes and pump RPM s along with data
62. ump cavitation 2 Seal on inserted valve damaged or missing 3 Broken weak valve spring s Worn damaged or corroded extension rod 2 Worn oil stop head seal 3 Oil level too high 4 Excessive crosshead wear o Pressure in crankcase 6 Misalignment in front Page 29 1 Check and adjust clearances 2 Reverse rotation 3 Check and tighten Replace if damaged 4 Check and tighten Replace if damaged 5 Replace 6 Replace 7 Replace 8 Replace 9 Replace 10 Replace 11 See Excessive Valve Noise problem 12 See Cavitation Fluid Knock or Hammer problem a See Cavitation Fluid Knock or Hammer problem 2 Replaced seal or valve 3 Replace spring s a Replace extension rod 2 Replace seal 3 Reduce oil level 4 Replace crosshead 5 Clean or replace air breather 6 Loosen bolts and center crosshead guide cover PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Oil Seal Leakage 1 Worn sealing lip 1 Replace seal 2 Damaged sealing lip 2 Replace seal 3 Outside diameter not seated 3 Clean and polish bore of oil seal housing 4 Shaft rough at seal lip 4 Clean and polish shaft or replace wear sleeve 5 Pressure in crankcase 5 Clean or replace air breather Stuffing Box Leakage 1 Short plunger packing life 1 See Short plunger Packing Life problem 2 Worn packing rings metal 2 Replace packing rings metal 3 Seal leaking at
63. verse steps 1 through 7 above to before assembling in the frame complete installation 2 Heat the inner bearing races before installing on crankshaft 250 F max oven or oil bath Braze the retaining rings on the crankshaft Avoid direct contact with the inner race or the crankshaft Reinstall the safety wire and or Loctite the bolts holding the bull gears to the crankshaft Failure to follow these directions may result in serious damage to the pump AN WARNING Do not drive against rollers or bearing cage Drive only against the bearing race as severe damage to the bearings could occur Page 26 SECTION 5 TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Pump Overloads Driver 1 Excessive pump speed and or discharge pressure 2 Blockage or closed valve in discharge line 3 Incorrect plunger size 4 Improper bypass conditions Fluid Not Delivered 1 Pump not primed 2 Air or vapor pocket in suction line 3 Clogged suction line 4 Suction and or discharge valves propped open Low Discharge Pressure 1 Worn or fluid cut valve 2 Valve propped open 3 Pump cavitating 4 Fluid leakage 5 Erroneous gauge reading Low Suction Pressure 1 Low head NPSH 2 Insufficient charging pump capacity 3 Retarded fluid flow 4 Erroneous gauge reading Page 27 Reduce pump speed and or pressure Clean or open valve Install the
64. when the triplex pump operates at its maximum flow The first startup is performed at the factory during the acceptance tests as a part of quality assurance procedure However the new pump break in period process may continue for the first 80 100 hours of our operation and therefore it will be each user s responsibility to perform all the tasks related to this critical period As all moving parts of the pump go through a wearing in process steel and bronze wear particles are carried by the oil flow in the lubrication system The resulting contamination of the lubrication system with the wear particles and especially clogging of the strainer and the oil filter can cause serious problems To assist the user the following guidelines are presented for the maintenance personnel to follow during the critical startup and break in period 1 Fill the lube oil reservoir with the recommended grade of oil See FIGURE 3 1 above for Lubricant Recommendations Page 16 10 11 12 Fill the plunger reservoir with proper oil See Plunger Packing Lubrication Recommendations on Page 19 Remove all inspection covers on the top of the pump frame Start the engine at the lowest possible RPM and triplex pump at zero 0 pressure Make sure that all roller bearings crossheads knuckle joints and crankshaft bearings have proper lubrication Increase the engine RPM to maximum operating speed and check whether the vacuum reading at

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