3-600/6 6/97 Duplex Pump Operating and Service Manual
Contents
1. 10 Foreword ii Frame Oil Stop Head 9 FXE Main Gear and Eccentric 13 Hammer Lug Fasteners Danger Notice 1 High Pressure Liquid Jetting Blasting and Cleaning Danger Notice 5 High Pressure Pistons for Abrasive Service 9 High Pressure Special Fluid Service 8 High Temperature Service 9 Hydraulic Puller Danger Notice 2 Inspection Occasional 12 Installation ihre behead here pete Khata 7 INSTALLATION AND OPERATING INSTRUC TIONS SECTION 2 7 Installation of Jackshaft Oil Seals 12 Jackshaft Removal 12 Lifting and Moving Equipment Danger Notice 2 Liners Fluid Cylinder 10 Low Pressure Water or Boiler Feed Service 8 Lubrication eee 8 Main Bearings Install 13 Moving and Lifting Equipment Danger Notice 2 Occasional Inspection 12 Operating Speeds and Pressures 14 Ordering Instructions Repair Parts i Packing Fluid Cylinder Liner 9 Fluid Piston Rod 9 Frame Oil Stop Head 9 Packing and Fluid Pistons 82. 12 DANGER NOTICES SECTION 1 1 Danger Notices Covers and Guards 2 Equipment Moving and Lifting 2 Flammable Hot Cold or Corrosive Fluid PUMPING x esee Dei iere 4 Hammer Lug Fasteners 1 High Pressure Liquid Jetting Blasting and Cleaning 5 Hydraulic 2 Pressurized Pump Systems 3 Valve Seat Pulling 2 Wedge Puller 2 Data for FXE and FXX Power Pumps 16 Data for FXG and FXF Power Pumps 17 Dimensions Fluid End Piston Rod Stuffing Box 15 Power End Oil Stop Head 15 DIMENSIONS amp RUNNING CLEARANCES SECTION Arrana ya a 15 Equipment Moving and Lifting Danger Notice 2 Flammable Hot Cold or Corrosive Fluid Pumping Danger Notice 4 Fluid Cylinder Liner Packing 9 Fluid Cylinder Liners 10 Fluid Discharge Piping 7 Fluid ENC Parts 10 Fluid End Piston Rod Stuffing Box Dimensions 15 Fluid Inlet or Suction Piping 7 Fluid Piston Rod Baffle 9 Fluid Piston Rod Packing 9 Fluid Pistons and Packing 8 3 600 Fluid Valves
3. Kl nit h Z Z ZZ 2 FM Z 77 27 Z uL ue C37353 FIGURE 8 JACKSHAFT ASSEMBLY Daily Care The pump should be kept clean lubri cated properly and stuffing boxes examined daily With reasonable care the pump can be expected to give long and trouble free life Occasional Inspection It is recommended that the fluid valves be examined occasionally to see that ex cessive wear or cutting has not impaired their efficiency and any damaged or worn parts should be replaced Fluid end must always be drained when exposed to freezing weather during idle periods SERVICE INSTRUCTIONS Removal of Jackshaft To remove the jackshaft it is necessary to remove the bearing housings from both sides of the pump The bearing outer races and rollers come off with the housings The bearings inner races and the seal bushings are pressed on the jackshaft and need not be removed unless replacement is necessary The jackshaft can be lifted clear of the gear teeth and removed The jackshaft is not interchangeable end for end hence it must be reinstalled in the same way it was removed Installation of Jackshaft Oil Seals The jackshaft roller bearings are provided with a separate inner and outer oil seal The correct assembly of these seals is with seal lips facing bearings To Remove Crosshead Pin From FXF and FXG Pumps The crosshead pin can be removed from the FXF and FX
4. cluding but not limited to engine or motors drive shafts belts chains pulleys gears etc must be equipped with guards or covers which must also be securely fastened in proper position at all times when the equip ment is operating Covers and guards are intended to not only protect against personal injury or death but to also protect the equipment from damage from foreign objects EQUIPMENT MOVING AND LIFTING A DANGER Heavy equipment including pumps pump package units and components should only be moved or lifted by trained experienced operators who are physically and mentally prepared to devote full attention and alert ness to the moving and lifting operations An operator should be fully aware of the use capabilities and condition of both the equipment being moved and the equipment being used to move it A 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 fal ling or other unexpected or uncon trolled equipment movements Make sure the hoist lift truck ropes slings spreader or other lifting equipment you are usingis in good condi tion 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 confor mance to rated load capacity They should then be tagged with the inspect
5. ANY IMPLIED WARRANTY OF MER CHANTABILITY THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE THE SOLE EXCLUSIVE AND ONLY REM EDY AVAILABLE TO PURCHASER AND IN NO CASE SHALL THE COMPANY BE SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES EXPENSES LOSSES OR DELAYS HOWSOEVER CAUSED No statement representation agreement or under standing 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 of ficer of the Company 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 com menced 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 Gardner ver For additional information contact your local representative or Gardner Denver Machinery Inc Customer Service Department 1800 Gardner Expressway Quincy Illinois 62301 gt Telephone 800 682 9868 FAX 217 224 7814 For parts information contact Gardner Denver y Master Distribution C
6. PISTON TEXTURES Maximum rated service temperature is 250 F Rod packings should always be installed in a clean stuffing box Each ring should be firmly seated by tamp ing as it is applied When box is full gland nuts should be tightened with a wrench just enough to seat the packing properly then slacken off and tighten nuts by hand locking the gland with a final quarter turn with a wrench DO NOT TIGHTEN GLANDS TOO TIGHT Some fluids require special packing and should be re ferred to the factory Fluid Piston Rod Baffle All pumps are supplied with an oil resistant rubber baffle which is mounted on the piston rod between the piston rod stuffing box and the oil stop head The baffle must be kept in place to pre vent foreign material following along the piston rod from the stuffing box into the power end Warranty is void if this baffle is not in place Frame Oil Stop Head Packing Oil stop head pack ing is cut square fibrous rings The packing should be inspected frequently and adjusted if necessary Re place when worn Fluid Cylinder Liner Packing Current liner packing construction consists of two square rubber hydraulic rings with a metal spacer between them andis suitable for most services 3 600 Page9 Never tighten liner jack screws while pump is running If the screws are drawn up too tight enough pressure can be put on the packing to crush the liner This ruins the liner is apt to ruin the pis
7. Piping aste sae eee Elec te 7 Fluid Discharge 7 Fluid Inlet or Suction 7 Suction or Fluid Inlet 7 Piston Fluid apa 8 PISTONVROOS cheek late aY 10 Power End Oil Stop Head Dimensions 15 Pressures and Operating Speeds 14 Pressurized Pump Systems Danger Notice 3 Page iv Recommended Running Clearances FXD FXE and FXX Power Pumps 16 FXG and FXF Power Pumps 17 Relief Valve 7 Repair Parts Ordering Instructions i Repair Parts Maintenance 13 Repair Parts Ordering 13 Rods Piston 10 ROUTINE MAINTENANCE amp SERVICE INSTRUCTIONS SECTION 12 Service Abrasive High Pressure Pistons 9 Boiler Feed 8 Clean Oil or Petroleum Products 9 High Pressure Special Fluid 8 High Temperature 9 Low Pressure Water 8 Specifications Torque 18 Starting a New Pump 10 Storage of Pump Special Care 14 Suction or Fluid Inlet Piping 7 Torque Specifications 18 TROUBLESHOOTING SE
8. crankcases of each size pump are as follows Power U S Imperial Incheg_mm End Gallons Gallons FIGURE 2 LUBRICATION FILL RATE Oil must be added as required to maintain the level to the top of the street elbow in the end of the frame Time between oil changes depends upon local conditions However if crankcase is kept closed it should not be necessary to change oil any more than each 1000 working hours Jackshaft and eccentric shaft roller bearings are sealed off from the crankcase lubricant and are provided with pressure gun grease fittings A reliable multipurpose 1 16 1 5875 mm For Widths Of Packing Up To 3 76 2 mm 1 8 3 175 mm For Packing Widths Beyond 3 76 2 mm Square Packing Rings J Z lt pg 22 A38627 WN FIGURE 3 PACKING TYPE PISTON grease NLGI Grade No 2 should be supplied to these with discretion Roller bearings WILL HEAT IF TOO MUCH GREASE is used especially if bearing is com pletely filled with grease FLUID PISTONS AND PACKING Four general types of fluid pistons and packings are used depending upon operating conditions or requirements The pumps are packed at the factory complete Low Pressure Water or Boiler Feed Service For low pressure water or boiler feed service use iron or bronze follower type pistons with fibrous duck and rub ber rings having regular or rock hard cure Regular cure rings are recommended for fluids w
9. service rods use one elastic collar type locknut per rod Rods should be threaded into the crosshead as shown in FIGURE 6 leaving approximately one thread of the locknut over the relieved portion of the rod as a protection to the threads FLUID VALVES Valves are easily installed in their in dividual valve pots Care should be exercised to tighten the valve cover nuts as uniformly as possible tighten ing each nut a little at a time until all are tight Valve 3 600 Crosshead Piston Rod BU A25062 FIGURE 6 PISTON ROD seats and the bore in the deck must be perfectly clean and free from oil or grease Valve seats can be removed with a puller which can be purchased from Gardner Denver Machinery Inc STARTING A NEW PUMP Pumps are shipped from the factory without oil in the crankcase The hood should be removed and the power end examined and cleaned if necessary The pump may have been in stor age or in the yard for some time and as a consequence dirt may have entered the crankcase Parts may have been robbed from the pump during storage and not re placed All nuts and screws should be tightened The jackshaft bearings have been supplied with grease at the factory and no grease should be added at this time unless bearings have been disturbed Be sure all valves in the discharge line are open No valve should be installed between the pump and pres sure relief valve in discharge line To prevent excessive we
10. this machine the owner must exercise care in its operation and maintenance This book is written to give the operator and maintenance department essential information for day to day opera tion maintenance and adjustment Careful adherence to these instructions will result in economical operation and minimum 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 Warning is used to indicate the presence of a hazard which can cause severe person al injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance information which is important but not hazard related 3 600 Page ii TABLE OF CONTENTS I IrOd gllop En i Repair Parts Ordering Instructions DRE x ONE ERR LES ERR ER EET i FOL GWOLOU eoe eub d eu mau s ode a DOS ii oos oed nr a REESE hU upa Qatu Da e Me cS e a iii Index EI Aem etai i Ll E Beet ehh EU xe CEDE RE iv Danger Notices Section ssp cesar ood atero le marin de NO eu Rd aden eure me esee a pare 1 Installation and Operating Instructions Section 2 7 Routi
11. CTION 5 19 Valve Relef 2 ee ees ean 7 Valve Seat Pulling Danger Notice 2 Valves Fluid 10 Warranty Last Page Wedge Puller Danger Notice 2 3 600 Pagev SECTION 1 DANGER NOTICES A DANGER Read and understand the following DANGER NO TICES before moving or operating the pump or any pump package unit equipment Reciprocating pumps are machines capable of produc ing high fluid pressures and flow rates and are de signed to be used with proper care and caution by trained experienced operators TO AVOID PER SONAL INJURY DEATH AND OR EQUIPMENT DAMAGE READ AND THOROUGHLY UNDER STAND THE FOLLOWING DANGER NOTICES PLUS THE ENTIRE OPERATING AND SERVICE MANUAL BEFORE ATTEMPTING TO MOVE OR OPERATE THE PUMP Contact a Gardner Denver Machinery service representative if you are unable to comply with any of the danger notices or procedures described in these documents Closely examine the data plate upon pump delivery to become thoroughly familiar with the operating limits for this pump model The pump must never be operated at speeds pressures or horsepower exceeding the maximum values shown on the data plate or at speeds below the minimum shown Failure to ob serve the operating limits shown on the data plate could result in personal injury death and or equipment damage and will void the warranty Al terations to the pump or application of t
12. FRAME Actual 003 Feeler Gauge 229 Condemnable when crosshead knocks or clearance equals 1 524 JACKSHAFT ROLLER BEARING Condemnable between roller and race 016 018 406 457 3 600 Page 17 TORQUE SPECIFICATIONS FXD _ FXF FXE _ FXG FXX _ eepe e e e e e Fluid Cylinder to Frame Connecting Stud Nuts Fluid Cylinder 81 6 Head Stud Nut gt m mm gt gt lt gt dMourzagonouj l gt lt X FLUID CYLINDER TYPE Column 4 of Matrix Fluid Cylinder Liner Set Screw Suction Manifold to Fluid Cylinder Discharge Manifold to Fluid Cylinder Suction Manifold Flange Nut Discharge Manifold 150 Flange Nut Piston Rod Nut Slush Proof Rod FXE ONLY Main Gear to Eccentric Screw Refer to Unit Nameplate and Parts List Manual Matrix Column 4 for Fluid Cylinder Descriptions 3 600 Page 18 SECTION FIVE TROUBLESHOOTING FAILURE TO DELIVER REQUIRED VOLUME Pump not primed Insufficient speed c Fluid liner worn Suction lift too high Air leaks in suction or stuffing boxes f Foot valve too small or clogged g Suction pipe not immersed deep enough h Fluid piston packing worn Fluid valves worn Insufficient prime mover horsepower k Piston loose on rod FAILURE TO CREATE RATED PRESSURE Insufficient prime mover horsepower Slippage in drive c
13. G only by removing the entire gear assem 3 600 bly To remove the gear and eccentric it is necessary to remove the main shaft The main shaft must be re moved from the side of the pump in which the end of the shaft contains a 3 4 10 UNC tapped hole This is the end of the shaft that also contains the main shaft to ec centric key See FIGURE 9 It is advisable to have new shaft seals as these seals can rarely be used the GEAR amp ECCENTRIC MAIN SHAFT 3 4 10 UNC TAPPED C41817 FIGURE 9 ECCENTRIC AND MAIN SHAFT ASSEMBLY Page 12 A41503 FIGURE 10 CROSSHEAD PIN REMOVAL FXX amp FXE second time Remove shaft through eccentric with hammer and wood block and the bearing cone and seal bushing on the side opposite the tapped hole will slip off the shaft The gear assembly with connecting rods and cross heads can all be pulled out through the hood opening after the main shaft has been removed The piston rods of course must be screwed out of the crossheads be fore the assembly can be taken from the frame Cross head pins are straight and are held in place in the cross heads with set screws To Remove Crosshead Pin From FXX FXD and FXE Pumps The inspection plates on the sides of the frame should be removed Two hexagon head cap screws are used to hold the crosshead pin to the cross head These are the two screws in the corners of the plate over the crosshead pin Take these
14. GARDNER DENVER June 1997 DUPLEX POWER PUMP MODELS FXF 5 FXG 6 FXX 8 FXD 10 FXE 10 OPERATING AND SERVICE MANUAL Gardner Denver MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Gardner Denver and genuine pump parts are manufactured to original tolerances and designed for optimum dependability Design and material innova tions 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 distribu tor 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 in ventory of genuine parts and he is backed up for emer gency parts by direct access to the Gardner Denver Machinery Inc Master Distribution Center MDC in Memphis Tennessee Your authorized distributor can support your Gardner Denver and OPI pump needs with these services 1 Trained parts specialists to assist you in select ing the correct replacement parts 2 Repair and maintenance kits designed with the necessary parts to simplify servicing your pump Authorized distributor service technicians are factory trained and skilled in pump maintenance and repair They are ready to r
15. High back pressure Piston rings in fluid end binding Pistons improperly packed f Valves not holding g Leakage past fluid piston rings h Leakage past liner packing i Liners worn PUMP LOSES CAPACITY AFTER STARTING a Leaky suction line b Suction lift too great lt Entrained vapors in the fluid especially if fluid is warm PUMP VIBRATES a Fluid pistons improperly packed b Foundation not sufficiently rigid c Fluid piston packed too tight dj Fluid valves improperly seated e Improper discharge line NOISY FLUID VALVES a Usually due to air leaks or failure of the fluid end to completely fill due to faulty suction conditions b Valves not seating tightly 3 600 Page 19 Gardner ver GENERAL PROVISIONS AND LIMITATIONS Gardner Denver Machinery Inc the Company war rants to each original retail purchaser Purchaser of its new products from the Company or its authorized distrib utor 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 Any product which has in the Company s judg ment been subject to negligence accident im proper storage or improper installation or ap plication Any product which has not been operated or maintained in accor
16. any work or investigation is performed on the pump or pump systems Blockthe crankshaft from turning and make certain that all pump drive motor or engine start switches or starter controls are clearly tagged with warnings not to start the pump while repair work is in process Whenever the pump is operating continually monitor the entire suction discharge and pump lubricating sys tems for leaks Thoroughly investigate the cause for leakage and do not operate the pump until the cause of the leak has been corrected Replace any parts which are found to be damaged or defective When a gasketed joint is disassembled for any reason discard the used gasket and replace it with a new genuine Gar dner Denver gasket before reassembling the joint Due to the high working pressures contained by the fluid cylinder discharge manifold and discharge piping welding on these components is not recommended If welding on the discharge system cannot be avoided only experienced qualified welders should be used In addition the welded part should be hydrostatically proof tested in the shop with water or hydraulic fluid to one and one half times maximum discharge system working pressure with no observable fluid leakage be fore 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 conta
17. apors are present in the pumping site atmosphere an engine could continue to run on these vapors even after the en gine fuel line is shut off if an air inlet shut off is not used In addition on pumping units used where flammable or explosive vapors could form all electric motors used as power sources must be of explosion proof construction and all electrical components and wiring must meet the current National Electrical Code for explosive atmosp heres These precautions must be taken to avoid possible per sonal injury death and or equipment damage from ex plosion fire or burns HIGH PRESSURE LIQUID JETTING BLASTING AND CLEANING A DANGER Extreme caution must be exercised if any type of wand gun nozzle or any other pressure and flow directing de vice is attached to the pump dis charge system for use in jetting blasting cleaning etc This type of equipment must be used with utmost care by trained experienced opera tors High pressure fluid streams can either by direct contact or by propel ling loose objects cause serious per sonal injury or death to the operators and or other persons Pressure or flow directing devices often receive pres surized flow through flexible hoses which can burst if they are kinked cut abraded or are otherwise worn damaged or pressured above their rated capacity Pro tect the hose and connections from damage by people objects and vehicles A broken cut or otherwise b
18. ar on the fluid pistons and packing when starting remove a suction valve cover plate on each side of the fluid end and prime the pump Pump should be started slowly if possible and should be operated for several hours with practically no dis charge pressure Check oil level as it may be neces sary to add a small quantity of oil to compensate for that adhering to the walls of the crankcase and the moving parts The pump may then gradually be brought up to full speed and full working pressure Watch for undue heating or abnormal noise in the working parts Check all joints in the suction line to be sure there are no air leaks Make certain pump is rotating in the correct direction Refer to FIGURE 7 page 11 Page 10 LL 009 PREFERRED ROTATION OF ECCENTRIC I 200 NI s 7 al SSK i Z SEES a k SSNS NSS NW i ey jm SS SS NS gt T A lt lt NC m mmm Y i x I Y lt A M 2 54 des ap B NN 85 JO es m p AN y gt mm ES mm E 71 gt ay WS nw o por TT ve 52 FIGURE 7 ROTATION OF ECCENTRIC SECTION 3 ROUTINE MAINTENANCE amp SERVICE INSTRUCTIONS ini m ES SS y S OSS SS lt lt lt lt s ms p
19. ble when liner knocks or clearance equals n 3 CROSSHEAD PIN Feeler Gauge 0015 0015 Condemnable Replace pressed in type bushings when a 006 152 mm feeler gauge can be inserted between the pin and bushing or when the crosshead pin knocks CROSSHEAD OR SHOE TO FRAME Actual 013 127 Feeler Gauge 012 102 Condemnable when crosshead knocks or clearance equals JACKSHAFT ROLLER BEARING Condemnable between roller and race 016 018 406 457 GEAR RATIO 3 600 Page 16 DATA FOR FXG AND FXF POWER PUMPS POWER END AND STROKE RECOMMENDED RUNNING CLEARANCES FXG FXF Actual dimensions are for new pumps and are 6 In Sea 4 ian Stroke 5 In em 0 mm Stroke possible cumulative tolerances Condemnable indicates replacement necessary ETTMI E ROLLER TYPE MAIN BEARINGS Refer to Page 13 Bearing Preload 001T 003 025T 076T 001T 003T 025T 076T Condemnable when pitting scaling mis alignment excessive wear or noise occurs CONNECTING ROD LINER TO ECCENTRIC Actual 015 178 014 152 Feeler Gauge 014 152 013 127 Condemnable when liner knocks or clearance equals Feeler Gauge 0010 0127 0254 Condemnable Replace pressed in type bushings when a 006 152 mm feeler gauge can be inserted between the pin and bushing or when the crosshead pin knocks CROSSHEAD OR SHOE TO
20. ct with the fluid stream or by con tact with loose objects the fluid stream has propelled if the pump system is improperly used or if the fluid is misdirected or allowed to escape from defective or im properly maintained equipment FLAMMABLE HOT COLD OR CORROSIVE FLUID PUMPING A DANGER Extreme caution must be exercised by trained and experienced operators when flammable hot cold or corro sive fluids are being pumped in order to avoid personal injury death and or equipment damage due to explosion fire burn extreme cold or chemical attack Never operate a pump which is pumping hydrocarbons or other flammable hot cold or corrosive fluids when any part of the pump suction system or discharge sys tem is leaking Stop the pump immediately if any leak age 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 sys tem or discharge system Shield the pump suction 3 600 Page4 system and discharge system to prevent any flam mable hot cold or corrosive fluid leakage from dripping or spraying on any components flame sparks hot ob jects 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 w
21. dance with the recommen dations of the Company Components or accessories manufactured warranted and serviced by others 5 reconditioned or prior owned product Claims for items described in 4 above should be sub mitted 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 which in its judgment proved not to be as warranted within the applicable Warranty Period as follows Except for the products or components listed below the Warranty Period for all products is 1 250 hours of opera tion 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 whichev er occurs first Forged steel fluid cylinder is warranted for 90 days from date of installation 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 LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company represen tative or authorized service personnel for repair or re placement of any product or part
22. e 0 001 to 0 003 inches 0 0254 to 0 0762 mm of shims 8 Remove end plate and install remaining shims 9 Mount and secure plate FXE Main Gear and Eccentric This pump is constructed with a separate gear bolted to the eccen tric Refer to page 18 for screw torque specifications MAINTENANCE OF SPARE REPAIR PARTS Al though operating conditions vary widely itis suggested that a stock of spare replacement parts be maintained to insure against loss of pump operation It is consid ered good practice to keep spare fluid valves pistons piston rods packings gaskets etc on hand A recom mended list of such parts may be secured from Gard ner Denver Customer Service the Master Distribution Center MDC or your local authorized Gardner Den ver Distributor ORDERING OF REPAIR PARTS Repair parts lists with sectional views are available for any Gardner Den ver power pump and may be secured from Gardner Denver Customer Service the Master Distribution Center MDC or your local authorized Gardner Den ver Distributor Page 13 When ordering parts lists or repairs always give size and serial number of pump Serial number is stamped on the pump nameplate attached to frame and also on raised pad located on upper side of the power frame at the fluid cylinder end If the serial number cannot be identified obtain several photographic views of the power frame and fluid cylin ders including part numbers of principal ca
23. e pumps below 40 RPM as this will hinder proper lu brication 3 600 Page 14 SECTION 4 DIMENSIONS amp RUNNING CLEARANCES POWER END OIL STOP HEAD DIMENSIONS Rod Diameter Diameter Stuffing Box 3 fw Stuffing Box Net De Size Rod Diameter Diameter Stuffin pth Of g Box m FXF 4x5 101 6 x 127 0 15 16 23 8125 1 3 4 44 45 2 1 16 52 3875 FXG 5x6 127 0 x 152 4 1 13 16 46 0375 2 3 8 60 325 127 0 x 203 2 1 1 2 38 1 2 1 2 63 5 1 1 8 28 575 or 1 1 2 38 1 2 1 2 63 5 3 1 8 79 375 127 0 x 254 0 127 0 x 203 2 1 1 2 38 1 2 1 2 63 5 28 575 or 1 1 2 38 1 2 1 2 63 5 79 375 127 0 x 254 0 190 5 x 203 2 1 1 2 38 1 2 1 2 63 5 28 575 or 1 1 2 38 1 2 1 2 63 5 79 375 190 5 x 254 0 Refer to Unit Nameplate and Parts List Manual Matrix Column 4 for Fluid Cylinder Descriptions 3 600 Page 15 DATA FOR FXD FXE AND FXX POWER PUMPS POWER END AND STROKE RECOMMENDED RUNNING CLEARANCES FXD amp FXE FXX Actual dimensions are for new pumps and are 10 In Menem 0 pcm Stroke 8 In 2 Stroke possible cumulative tolerances Condemnable indicates replacement necessary w Em ROLLER TYPE MAIN BEARINGS Refer to Page 13 Bearing Preload 001T 003T 025T 076T 001T 003T 025T 076T Condemnable when pitting scaling mis alignment excessive wear or noise occurs CONNECTING ROD LINER TO ECCENTRIC Actual 011 022 279 559 017 Feeler Gauge 010 021 016 Condemna
24. ed capacity together with the date of inspection Fully assembled pumps and pump package units are heavy and should only be moved using the specified lifting lugs or attachments Many individual compo nents 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 lift ing the individual component check to insure the lifting attachment is firmly secured to the component with un damaged 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 con nected to the lifting attachments normally built into the package unit support skid Packages too large to lift ful ly assembled should be separated into smaller loads 3 600 2 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 dis charge pulsation dampener attached to a strainer cross and piping use special
25. enter Memphis TN Telephone 800 245 4946 FAX 901 542 6159 Specifications subject to change without notice Copyright 1997 Gardner Denver Machinery Inc Litho in U S A
26. espond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pages of your phone directory or contact Distribution Center Gardner Denver Machinery Inc Master Distribution Center 5585 East Shelby Drive Memphis TN 38141 Phone 901 363 6100 Fax 901 363 1095 Factory Gardner Denver Machinery Inc 1800 Gardner Expressway Quincy IL 62301 Phone 217 222 5400 Fax 217 224 7814 INSTRUCTIONS FOR ORDERING REPAIR PARTS When ordering parts specify Pump MODEL and SE RIAL 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 near est authorized distributor Where NOT specified quantity of parts required per pump or unitis 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 paren thesis following the part name i e RH amp LH when appropriate 3 600 Pagei FOREWORD Gardner Denver and OPI pumps are the result of advanced engineering and skilled manufacturing To be assured of receiving maximum service from
27. he pump out side the data plate limits must not be made without Gardner Denver Machinery written approval together with a new data plate as dangerous operating condi tions could result THE DANGER NOTICE AND DATA PLATES PRO VIDED ON THE EQUIPMENT MUST NOT BE RE MOVED PAINTED OVER HIDDEN OR DEFACED They must be replaced if they become damaged or un readable Provisions should be made to have the fol lowing written danger notices plus the pump operating and service manual readily available to operators and maintenance personnel In addition copies of all pump system accessory component e g pressure relief valve pulsation dampener suction stabilizer engine electric motor etc operating and service manuals should be readily available for operator and mainte nance personnel use Read and follow all the precau tions and instructions contained in these manuals If any of these documents are lost or become illegible they must be replaced immediately The danger no tices plus the operating and service manuals should be reread periodically by both operators and maintenance personnel to refresh their memories in safe procedures and practices Keep in mind that full operator attention and alertness are required when operating high pressure pumping equipment Operators should not begin or continue op erations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription drugs The time
28. hen other inherently less dangerous fluids are used Contact a Gardner Denver Machinery service representative for assistance in selecting the proper gaskets seals and packing before beginning operation Since some packing weepage into the cradle areais in evitable the drain at the bottom of the cradle must be connected to a drain line which conducts the fluid leak age 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 va pors the covers must be vented to conduct the fumes away from the pump unit to a nonhazardous area Before beginning pumping operations or starting the pump power source whether an engine or electric mo tor 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 flam mable or explosive vapors are detected Hot surfaces sparks electric current or engine exhaust could ignite flammable or explosive vapors Each engine used as a power source on pumping units where flammable or explosive vapors could form should be equipped with an air inlet shut off If flammable or explosive v
29. ith temperatures of 180 F 82 2 C or lower Rock hard rings should al ways be used for fluids with higher temperatures to 250 F 121 1 C maximum Ring lateral clearance between the follower and piston body flange is deter mined by the amount of packing Clearance should be 1 16 1 5875 mm for 3 76 2 mm width packing and under and 1 8 3 1 75 mm for width beyond 3 76 2 mm The rings should be installed with the end step cut joint gap of 1 32 7937 mm for 3 76 2 mm diam eter and under 1 16 1 5875 mm for 3 76 2 mm to 7 1 2 190 5 mm and 1 8 3 175 mm beyond 7 1 2 190 5 mm diameter All regular cure and rock hard piston packing should be soaked at least eight hours in warm water before installing High Pressure Special Fluid Service For high pres sure water and mildly abrasive fluids the cup type pis tons are recommended Pistons are available in bronze steel iron monel and stainless steel Fluids such as acids and alkalis require special cup composi tions and should be referred to factory for information To assemble the piston to the rod proceed as follows 1 Mount the hub to the taper 3 600 Page8 Thin Nut A41359 FIGURE 4 CUP TYPE PISTON Fit cup snugly to the hub Mount the spacing plate Mount the outer cup Ou Ocal Mount the follower plate and tighten the nut and locknut securely For the texture of the cups see FIGURE 5 Clean Oil or Petr
30. lifting slings designed to safely support the combined weight of the components If a crane or hoist is being used to lift large components or assemblies one or more persons should assist the operator from the ground with guide lines attached to the equipment being moved to properly position it and prevent uncontrolled movement When you start to pump package unit subassem blies 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 equip ment 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 A DANGER Fluids under high pressure can pos sess sufficient energy to cause per sonal injury death and or equipment damage either through direct contact with escaping fluid streams or by con tact with loose objects the pressur ized fluid propels Operating a pump against a blocked or restricted dis charge line can produce excessive pressures in the en tire discharge system which can damage or burst dis charge system components A DANGER Never operate a pump without a prop erly sized pressure relief valve lo cated in the flowing discharge line im mediately adjace
31. lowing this visual examination the hose assembly should be hydrostatically tested on test stands having adequate guards to protect the oper ator per the hose manufacturer s proof test procedure Fluid end component inspections should be per formed more frequently than every six months if pressures above 2500 psi are used in the dis charge system or if corrosive flammable or hot over 110 F fluids are being pumped Proper stuffing box packing selection is important for safe pump operation Contact a Gardner Denver Ma chinery service representative for assistance in select ing the proper packing before beginning operation Before starting the pump for the first time and periodi cally thereafter check the pump suction and discharge System fastener torques versus the values listed in the Operating and Service Manual tables 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 dis charge pressure of the pump A DANGER Do not attempt to service repair ad just the plunger packing or otherwise work on the pump while the unit is op erating Shut off the pump drive mo tor or engine and relieve the fluid pressure in the pump suction and dis charge systems before
32. ly 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 ex acting standards to provide high quality performance and durability Your best insurance in maintaining these characteristics is to use genuine Gardner Denver replacement parts A broad range of danger notices are covered on these pages however they cannot substitute for training ex perience and common sense in the safe operation of high pressure pumping equipment HAMMER LUG FASTENERS A DANGER On pumps or pump package units equipped with ham mer lug connectors and or hammer lug valve covers the following precautions must be observed to avoid personal injury death and or equipment damage due to contact with the hammer hammer bar broken parts from the hammer hammer bar or lugs or other objects propelled by hammer blows When tightening or loos ening hammer lug connectors and valve covers opera tors or maintenance personnel should Inspect the hammer hammer lugs and hammer bar if one is used to insure they are all good condition Replace any of these parts which are cracked damaged or badly worn Wear safety shoes and goggles Alert other personnel to move away from the area e Check to insure they have safe footing Fully engage the hammer bar if one is used to prevent it from disengaging violentl
33. ment or improperly fitted pipe Fluid Inlet or Suction Piping Inlet piping should be as direct and short as possible and should be laid out so that air pockets are eliminated The inlet pipe must never be smaller than the pump inlet and lines longer than 20 feet 6 meters including friction must never be exceeded To protect the pump from foreign matter an inlet strainer should be installed with a net area of four times the inlet pipe Fluid Discharge Piping It is advisable to use an am ple size discharge line to prevent excessive friction The use of an air chamber is recommended and ample size chambers are available for all pumps RELIEF VALVE Pump must be protected from ex cess pressure by a discharge pressure relief valve The valve must be installed near the pump preferably in the opening provided for it in the discharge manifold on models where applicable Never install a shutoff valve in the line between the relief valve and pump cylinder The relief valve should be set to operate at approxi mately 1 1 4 times the discharge pressure but must not exceed system equipment tolerances CRANKCASE OIL REQUIREMENTS API GL5 Oil Grade 75W 90 Ambient Temperature 20 to 90 F 29 32 10 F to 120 F 12 C to 49 C 80 10 F to 60 F 23 C to 16 C 90 20 F to 100 F 7 C to 38 C 140 50 F to 120 F 10 C to 49 C 80W 140 Crankcase Operating Cil Temperat
34. ne Maintenance amp Service Instructions Section 3 12 Dimensions amp Running Clearances Section 4 0 cece nett 15 TROUDIESHOOUNG SCONES anat cet Badan Euh DU aae iE tee tg ede 19 Warranty RP Last Page List of Illustrations Figure 1 Crankcase Oil Requirements 0 00 nnne eee 7 Figure 2 Lubrication Fill Rate bea RS SEE ee eee wee 8 Figure 3 Packing Type PISION x ox ai Ae beet ei oe 8 Figure 4 CUP Type PISION u ur edhe mene ee PUDOR ate 9 Figure 5 Piston TEXtUIOS oni taa E hese Sees he wet a Oe MY vida vede e we 9 Figure 6 Piston ROG Mee 10 Figure 7 Rotation of Eccentric 11 Figure 8 J ckshatt Assembly ety OD aod es 12 Figure 9 Eccentric and Main Shaft Assembly 12 Figure 10 Crosshead Pin Removal FXX amp FXE 13 3 600 Page INDEX Baffle Fluid Piston Rod 9 Boiler Feed or Low Pressure Water Service 8 Clean Oil or Petroleum Products Services 9 Covers and Guards Danger Notice 2 Crosshead Pin Removal FXF amp FXG Pumps 12 Crosshead Pin Removal FXX FXD amp FXG 13 Daily
35. nt to the pump dis charge connection The relief valve should be placed in the flowing dis charge line and not at the opposite end of the discharge manifold a dead end connection 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 pres sure 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 pres sure capability than that listed on the pump data plate the pressure relief valve must be setto relieve at a pres sure equal to or below the rated capability of the lowest rated component Before starting the pump every time check to in sure pressure relief valve is in good operating condition and has been set to the proper relief pressure Any pipe line used to direct pressurized relief flow to another location such as a collecting tank is not blocked e The discharge system is not blocked and all the discharge line valves are open Check all fluid end discharge system components including pi
36. oleum Products Service All Pres sures Solid metal pistons with grooves and metal snap rings or non metallic rings with expanders are recommended Piston ring grooves have the proper clearance but it is necessary to check rings for end clearance Insert each ring in the cylinder liner and check end clearance with a feeler gauge Metal rings should have from 003 076 mm to 004 1 02 mm per inch 25 4 mm of ring diameter and nonmetallic should have from 006 152 mm to 008 203 mm per inch 25 4 mm of ring diameter High Pressure Pistons For Abrasive Service For high pressure slush service or mud with abrasive par ticles a regular oil field rubber type piston is recom mended High Temperature Service Consult the Factory for recommendations Fluid Piston Rod Packing Braided synthetic pack ing is standard for water oil and general service Maxi mum service ratings for this packing are 250 PSI and 250 F Molded convex packing is standard for mud service Maximum rated service temperature is 180 F Molded rubber and duck packing is standard for grout and cement service and optional for other services Temperature Pressure Texture 20 F to 212 F 28 9 to 100 C 0 to 125 PSI 0 to 8 79 kg cm2 20 F to 300 F 100 to 500 PSI 28 9 C to 148 9 C 7 03 to 35 15 kg cm 30 F to 300 F 1 1 C to 148 9 C 500 to 1000 PSI 35 15 to 50 31 kg cm FIGURE 5
37. pe connections elbows threads fas teners hoses etc at least once every six months to confirm their structural adequacy With time wear corrosion and fatigue can reduce the strength of all components Magnetic iron and steel components should be checked with magnetic particle or dye pene trant crack detection equipment Nonmagnetic materi als should be checked for cracks with dye penetrants All metallic components should also be visually checked during these inspections for signs of corro sion 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 as semblies when the pump is operating for leakage kink ing abrasion corrosion or any other signs of wear or damage 3 600 Page3 Worn or damaged hose assemblies should be re placed immediately At least every six months ex amine 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 lay line 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 Fol
38. r 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 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 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 inju ry death and or damage to equipment Make sure the work area is checked for hazardous fumes has ade quate 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
39. reg ularly checked for condition These components should all be tagged with their tested pressure capabili ties together with the date testing was performed Al ways be aware of the pressure level in the system and never connect any equipment to the system which has a rated or tested pressure capability be low 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 a cold environment check to make sure there is no ice in the fluid system and re peat this inspection each time before operation is re started Before purchasing wands nozzles guns connections and hose etc manufacturers of these components should be contacted for detailed information on the de sign and safety features incorporated in their products After careful study of various manufacturers products we recommend that only those wands nozzle
40. s guns connections and hose etc be considered for pur chase that you judge to offer the highest quality of de sign construction and safety since these components are among the most critical to the safe operation of high pressure liquid jetting blasting and cleaning equip ment After you have selected and purchased these compo nents follow the manufacturer s instructions complete ly in their use In summary high pressure jetting blasting and cleaning are inherently dangerous as the pressur es 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 3 600 Page6 SECTION 2 INSTALLATION amp OPERATING INSTRUCTIONS FOR GARDNER DENVER FXF FXG FXX and DUPLEX POWER PUMPS INSTALLATION The pump should be installed as close to the fluid supply as possible Whenever pos sible ample space should be provided around the pump to facilitate inspection and adjustment with par ticular attention to the space required for removal and installation of piston rods liners and jackshafts Pump should be properly leveled and securely fas tened to whatever type of foundation is provided The drive must be accurately aligned PIPING All piping must be supported inde pendently of the pump to insure that no strain is imposed on the pump by misalign
41. screws out and insert them in the tapped holes in the adjacent cor ners of the plate and by exerting sufficient pressure with these screws the crosshead pin will come out A little persuasion with a drift driven against the cross head near the outer end of the crosshead pin will help To remove the gear and eccentric it is necessary to re move the main shaft and piston rods The main shaft must be removed from the side of the pump in which the shaft contains 3 4 10 UNC tapped hole This is the end of the shaft that also contains the main shaft to ec centric key See FIGURE 9 page 12 Support eccen tric on blocking and drive shaft through eccentric with hammer and wood block The bearing cone and seal sleeve on the side opposite the tapped hole will slip off the shaft 3 600 To Install Main Bearings For All Pumps 1 Install eccentric with gear teeth in correct position in frame 2 Install main shaft through opening in frame and through eccentric 3 Heat and press bearing cones to shaft 4 Install bearing cups There should be no space between the bearing cones and seal bushing or between the seal bushing and ec centric hub 5 Install gasket and end plate on one side 6 Take up end plate on other side snugly with cap screws 7 Check the gap between plate and frame housing with shims Determine shims required to fill the gap When you have determined the shims re quired to fill the gap remov
42. stings which should furnish us clues as to the identity of the pump SPECIAL CARE OF PUMP IN STORAGE Piston rod packing and piston packing must be removed if the pump is not put in service immediately Permitting packing to remain in an idle pump for a period of time will tend to create rusting and pitting of liner bore and piston rods Puller kit parts for removing valve seats liners and crosshead pin bushings may be purchased from Gard ner Denver Machinery Inc OPERATING SPEEDS AND PRESSURES See bul letins for operating speeds and pressures for type of service All displacements are theoretical with piston rod vol ume deducted For actual delivery deduct from 5 to 10 for slippage using 10 at maximum RPM A DANGER Pressures are maximum permissible with rated maximum piston rod loads and MUST NEVER BE EXCEEDED While it is true that reducing the speed reduces the horsepower practically in direct proportion the piston load for which the pump is designed is a function of the fluid pressure against the piston Reducing the speed to half and doubling the pressure requires approxi mately the same horsepower but results in 100 over load on the power end Maximum input BHP and shaft RPM shown in bulletins MUST NEVER BE EXCEEDED under any operating conditions These speeds are recommended for favor able suction conditions and consideration must be giv en to viscosity and character of fluid DO NOT operate thes
43. thereof which in the Company s judgment is proved not to be as warranted BE 13 R 10 96 WARRANTY GARDNER DENVER e OPI PUMPS 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 ser vice 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 Pur chaser 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 war ranty 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 WARRANTY REGISTRATION VALIDATION A warranty registration form is provided with each ma chine The form must be completed by the Purchaser and mailed within ten days after machine start up to vali date the warranty DISCLAIMER THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS EXPRESSLY AGREED THAT EXCEPT AS TO TITLE THE COMPANY MAKES NO OTHER WAR RANTIES EXPRESSED IMPLIED OR STATUTORY INCLUDING
44. ton and can cause piston rod breakage Whenever the cylinder head is removed for any reason the liner jack screws must be backed out Jack screws should be greased to increase life of screws and cylin der heads and also to prevent rust formation When the cylinder head is replaced the head to cylin der stud nuts should be tightened completely AFTER the head nuts are tight the liner jack screws should be adjusted against the liners and the locknuts tightened Be sure packing is installed under set screw nuts to pre vent leakage Some pumps are equipped with a clamp located against the end of the liner and serves as a face for the set screws to bear against For the proper tightening torques refer to torque table page 18 FLUID END PARTS Standard procedure for shipping pumps from the Factory is with valves pistons liners piston rods and packing installed These fluid end ex pendable parts are shipped unassembled only when requested by the customer FLUID CYLINDER LINERS Liners should be installed in accordance with instructions given under heading Fluid Cylinder Liner Packing page 9 Clean liners thoroughly and grease the outside diameter be fore installing Liner jack screws should be tightened as uniformly as possible PISTON RODS Pistons should be assembled on the rod taper WITH THE THIN NUT NEXT TO THE PIS TON HUB AND THE THICK NUT ON THE OUTSIDE This is important as the outer nut carries the load Slush
45. ure 60 to 170 F 16 C to 77 C 90 F to 200 F 32 C to 93 C 70 F to 140 F 21 C to 60 C 100 F to 180 F 38 C to 82 C 130 F to 200 F 54 C to 93 Minimum Startup Oil Temperature 20 F 7 C 50 F 10 C 30 F 1 C 60 F 16 C 80 F 27 C An 80 F 27 C crankcase oil temperature rise over ambient air temperature is typical for the pumps covered by this manual when operating at or near rated horsepower FIGURE 1 CRANKCASE OIL REQUIREMENTS 3 600 Page7 A DANGER Improper use or maintenance of relief valves can cause excessive pressure which may result in property damage and or serious personal injury or death When the pump is equipped with Shear Type Relief Valve use only one Shear Pin of the size shown on the setting plate The use of a nail or any shear device other than Vendor Shear Pin may be extremely hazardous Do not hammer on shear bar or stem or shear bar slot LUBRICATION Recommended crankcase oils are as shown in FIGURE 1 page 7 Oil viscosity must not exceed 7000 SSU at startup and must be between 1500 SSU and 130 SSU while operat ing regardless of the oil temperature or grade used A crankcase heater and or an oil heat exchanger may be needed to meet these requirements Failure to follow these lubrication requirements will void the warranty The approximate quantities of lubricant required to properly fill the
46. urst 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 operator s ability to control or direct the device which could lead to personal injury death and or equipment damage The operator must brace against the back ward 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 ina 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 pres sure 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 circum 3 600 Page5 vent the automatic shut off for any reason o
47. y from the cover as a blow is struck e 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 strik ing 3 600 1 Carefully swing the hammer to avoid striking themselves another person and objects other than the targeted lugs or hammer bar e Avoid swinging the hammer above shoulder height VALVE SEAT PULLING A DANGER The following precautions must be observed by opera tors and maintenance personnel to avoid personal inju ry death and or equipment damage from contact with the puller hammer wedge or broken parts from these components when using either a hydraulic or wedge valve seat puller Hydraulic Puller e Wear safety shoes and goggles e Chainortiethe jack down as it will jump violently when the valve seat disengages from the valve deck e Check to insure the pressure applied by the hy draulic pump does not exceed the hydraulic ram maximum pressure rating Wedge Puller e Grind off any mushroomed material from the wedge before use Follow the danger notices listed above in the hammer lug section but substitute the term wedge for hammer lug and hammer bar COVERS AND GUARDS A DANGER All pump covers must be securely fastened in proper position at all times when the pump is operating to avoid personal injury or death from moving parts In addition all moving parts on the entire pump package in
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