GARDNER DENVER

TRIPLEX

PLUNGER PUMP

MODELTEE

5 STROKE

OPERATING ANDSERVICE MANUAL

316065th EditionJune, 1997

31606 Page i

MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITHGENUINE GARDNER DENVER

PARTS AND SUPPORT SERVICES

Gardner Denver and OPI genuine pump parts aremanufactured to original tolerances and designed foroptimum dependability. Design and material innova-tions are the result of years of experience withhundreds of different pump applications. Reliability inmaterials and quality assurance are incorporated in ourgenuine replacement parts.

Your authorized Gardner Denver and OPI distribu-tor offers all the backup youll need. A worldwidenetwork of authorized distributors provides the finestproduct support in the pump industry.

Your local authorized distributor maintains a large in-ventory of genuine parts and he is backed up for emer-

gency parts by direct access to the Gardner DenverMachinery Inc. Master Distribution Center (MDC) inMemphis, Tennessee.Your authorized distributor can support your GardnerDenver and OPI pump needs with these services:1. Trained parts specialists to assist you in select-

ing the correct replacement parts.2. Repair and maintenance kits designed with the

necessary parts to simplify servicing your pump.Authorized distributor service technicians are factorytrained and skilled in pump maintenance and repair.They are ready to respond and assist you by providingfast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pagesof your phone directory or contact:

Distribution Center: Factory:Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.Master Distribution Center 1800 Gardner Expressway5585 East Shelby Drive Quincy, IL 62301Memphis, TN 38141 Phone: (217) 2225400Phone: (901) 5426100 Fax: (217) 2247814Fax: (901) 5426159

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL and SE-RIAL NUMBER (see nameplate on unit). The SerialNumber is also stamped on top of the cylinder end ofthe frame (cradle area).All orders for Parts should be placed with the near-est authorized distributor.Where NOT specified, quantity of parts required perpump or unit is one (1); where more than one is required

per unit, quantity is indicated in parenthesis. SPECIFYEXACTLY THE NUMBER OF PARTS REQUIRED.DO NOT ORDER BY SETS OR GROUPS.To determine the Right Hand and Left Hand side of apump, stand at the power end and look toward the fluidend. Right Hand and Left Hand are indicated in paren-thesis following the part name, i.e. (RH) & (LH), whenappropriate.

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FOREWORD

Gardner Denver and OPI pumps are the result of advanced engineering and skilled manufacturing. To be assuredof receiving maximum service from this machine the owner must exercise care in its operation and maintenance.This book is written to give the operator and maintenance department essential information for daytoday opera-tion, maintenance and adjustment. Careful adherence to these instructions will result in economical operation andminimum downtime.

Danger is used to indicate the presence of a hazard which will cause severe personalinjury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe person-al injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minorpersonal injury or property damage if the warning is ignored.

Notice is used to notify people of installation, operation or maintenance informationwhich is important but not hazardrelated.

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TABLE OF CONTENTS

Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and Support Services i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions For Ordering Repair Parts i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Illustrations iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1, Danger Notices 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2, Operating and Maintenance Instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plunger Packing Lubrication Recommendation Chart 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gardner Denver Horizontal Pump Recommended System Layout for ProperPerformance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Net Positive Suction Head Required (NPSHR)* at Fluid Cylinder Suction Connection withSuction Stabilizer and Discharge Pulsation Dampener Installed 24. . . . . . . . . . . . . . . . . . . . . . . . . .

Correction Chart for Temperature or Viscosity 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viscosity Conversion Table 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3, TroubleShooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4, Rebuilding Data, Running Clearances and Torque Specifications 32. . . . . . . . . . . . . . . . . . . . .

For Part List Refer to: MANUAL 31529

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INDEX

Bearings, Main 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosive Attack, Fluid End 18. . . . . . . . . . . . . . . . . . . . Covers and Guards, Danger Notice 2. . . . . . . . . . . . . . Crankcase Oil Requirements 21. . . . . . . . . . . . . . . . . . Crosshead and Pins 18. . . . . . . . . . . . . . . . . . . . . . . . . .

DANGER NOTICES, SECTION 1 1. . . . . . . . . . . . . . . Danger Notices

Covers and Guards 2. . . . . . . . . . . . . . . . . . . . . . . . Equipment Moving and Lifting 2. . . . . . . . . . . . . . . Flammable, Hot, Cold or Corrosive Fluid Pump-

ing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer Lug Fasteners 1. . . . . . . . . . . . . . . . . . . . High Pressure Liquid Jetting, Blasting and Clean-

ing 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Pump Systems 3. . . . . . . . . . . . . . . . . Valve Seat Pulling 2. . . . . . . . . . . . . . . . . . . . . . . . . Wedge Puller 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disc Valves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Eccentric 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric Shaft Assembly Procedure 19. . . . . . . . . . . . Equipment Moving and Lifting, Danger Notice 2. . . . . Extension Rod 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter, Oil 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flammable, Hot, Cold or Corrosive Fluid Pumping,

Danger Notice 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Cylinders 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid End Corrosive Attack 18. . . . . . . . . . . . . . . . . . . . Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hammer Lug Fasteners, Danger Notice 1. . . . . . . . . . Heat Exchanger, (Optional Equipment) 11. . . . . . . . . . High Pressure Liquid Jetting, Blasting and Cleaning,

Danger Notice 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Puller, Danger Notice 2. . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION AND OPERATING INSTRUC-

TIONS, SECTION 2 8. . . . . . . . . . . . . . . . . . . . . . . . Lifting and Moving Equipment, Danger Notice 2. . . . . Liners, Piston, and Liner Clamps 17. . . . . . . . . . . . . . . Location 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication, Power End 9. . . . . . . . . . . . . . . . . . . . . . . . Lubricator, Packing 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearings 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving and Lifting Equipment, Danger Notice 2. . . . .

Net Positive Suction Head Required 24. . . . . . . . . . . .

Oil Filter 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Stop Heads 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Instructions, Repair Parts i. . . . . . . . . . . . . .

Packing, Plunger 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing Lubricator 16. . . . . . . . . . . . . . . . . . . . . . . . . . . Piping, Suction 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Liners and Liner Clamps 17. . . . . . . . . . . . . . . . Piston Rod 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Washing System 17. . . . . . . . . . . . . . . . . . . . . . . Pistons 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger Packing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plunger Packing Lubrication Recommendation Chart

22Rock Drill Lubricants 22. . . . . . . . . . . . . . . . . . . . . . Steam Cylinder Oils 22. . . . . . . . . . . . . . . . . . . . . . .

Plungers 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power End, Lubrication 9. . . . . . . . . . . . . . . . . . . . . . . . Pressure Relief Valve 8. . . . . . . . . . . . . . . . . . . . . . . . . . Pressurized Pump Systems, Danger Notice 3. . . . . .

Rebuilding Data 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REBUILDING DATA, RUNNING CLEARANCES

AND TORQUES, SECTION 4 32. . . . . . . . . . . . . . Repair Parts, Ordering Instructions i. . . . . . . . . . . . . . Rod

Connecting 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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INDEX (Continued)

Extension 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running Clearances Actual 32. . . . . . . . . . . . . . . . . .

Service InstructionsFluid End 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power End 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting a New Pump 11. . . . . . . . . . . . . . . . . . . . . . . . . Stop Heads, Oil 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stuffing Boxes 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Piping 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Layout, Horizontal Pump 23. . . . . . . . . . . . . . .

Tapered Seat Valves 12. . . . . . . . . . . . . . . . . . . . . . . . . . Temperature or Viscosity, Correction Chart 25. . . . . .

Torques 32, 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING, SECTION 3 27. . . . . . . . . . . TroubleShooting 27 thru 31. . . . . . . . . . . . . . . . . . . . .

Valve, Pressure Relief 8. . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat Pulling, Danger Notice 2. . . . . . . . . . . . . . . Valves

Disc 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tapered Seat 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . Wing Guided and Severe Duty 14. . . . . . . . . . . . .

Viscosity Conversion Table 26. . . . . . . . . . . . . . . . . . . . Viscosity or Temperature, Correction Chart 25. . . . . .

Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge Puller, Danger Notice 2. . . . . . . . . . . . . . . . . . . Wing Guided and Severe Duty Valves 14. . . . . . . . . . .

LIST OF ILLUSTRATIONS

Figure # Description Page

Figure 1 Sectional View of TEE Triplex Plunger Pump 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2 Auxiliary Oil Pump Diagram 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3 Heat Exchanger Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4 Sectional View of Fluid Cylinder 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5 Sectional View Showing Eccentric 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6 Eccentric Shaft Positioning 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7 Crankcase Oil Requirements 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 1DANGER NOTICES

Read and understand the following DANGER NO-TICES before moving or operating the pump or anypump package unit equipment.

Reciprocating pumps are machines capable of produc-ing high fluid pressures and flow rates and are de-signed to be used with proper care and caution bytrained, experienced operators. TO AVOID PER-SONAL INJURY, DEATH AND/OR EQUIPMENTDAMAGE, READ AND THOROUGHLY UNDER-STAND THE FOLLOWING DANGER NOTICESPLUS THE ENTIRE OPERATING AND SERVICEMANUAL BEFORE ATTEMPTING TO MOVE OROPERATE THE PUMP. Contact a Gardner DenverMachinery service representative if you are unable tocomply with any of the danger notices or proceduresdescribed in these documents.

Closely examine the data plate upon pump delivery tobecome thoroughly familiar with the operating limits forthis pump model. The pump must never be operatedat speeds, pressures or horsepower exceeding themaximum values shown on the data plate or atspeeds below the minimum shown. Failure to ob-serve the operating limits shown on the data platecould result in personal injury, death, and/orequipment damage and will void the warranty. Al-terations to the pump, or application of the pump out-side the data plate limits, must not be made withoutGardner Denver Machinery written approval togetherwith a new data plate, as dangerous operating condi-tions could result.

THE DANGER NOTICE AND DATA PLATES PRO-VIDED ON THE EQUIPMENT MUST NOT BE RE-MOVED, PAINTED OVER, HIDDEN OR DEFACED.They must be replaced if they become damaged or un-readable. Provisions should be made to have the fol-lowing written danger notices plus the pump operatingand service manual readily available to operators andmaintenance personnel. In addition, copies of all pumpsystem accessory component (e.g. pressure reliefvalve, pulsation dampener, suction stabilizer, engine,electric motor, etc.) operating and service manualsshould be readily available for operator and mainte-nance personnel use. Read and follow all the precau-tions and instructions contained in these manuals. Ifany of these documents are lost or become illegiblethey must be replaced immediately. The danger no-tices plus the operating and service manuals should be

reread periodically by both operators and maintenancepersonnel to refresh their memories in safe proceduresand practices.

Keep in mind that full operator attention and alertnessare required when operating high pressure pumpingequipment. Operators should not begin or continue op-erations when tired, distracted or under the influence ofalcohol or any type of prescription or nonprescriptiondrugs.

The timely replacement of expendable parts and anyother worn or damaged parts can prevent equipmentdamage and possible injury. The original parts used inGardner Denver pumps are designed and tested to ex-acting standards to provide high quality performanceand durability. Your best insurance in maintainingthese characteristics is to use genuine Gardner Denverreplacement parts.

A broad range of danger notices are covered on thesepages, however, they cannot substitute for training, ex-perience and common sense in the safe operation ofhigh pressure pumping equipment.

HAMMER LUG FASTENERS

On pumps or pump package units equipped with ham-mer lug connectors and/or hammer lug valve coversthe following precautions must be observed to avoidpersonal injury, death and/or equipment damage dueto contact with the hammer, hammer bar, broken partsfrom the hammer, hammer bar or lugs or other objectspropelled by hammer blows. When tightening or loos-ening hammer lug connectors and valve covers, opera-tors or maintenance personnel should:

Inspect the hammer, hammer lugs and hammerbar, if one is used, to insure they are all in goodcondition. Replace any of these parts which arecracked, damaged or badly worn.

Wear safety shoes and goggles. Alert other personnel to move away from the

area.

Check to insure they have safe footing. Fully engage the hammer bar, if one is used, to

prevent it from disengaging violently from thecover as a blow is struck.

Wipe their hands and the hammer handle andmaintain a firm grip on the handle to avoid los-

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ing control of the hammer while swinging andstriking.

Carefully swing the hammer to avoid strikingthemselves, another person and objects otherthan the targeted lugs or hammer bar.

Avoid swinging the hammer above shoulderheight.

VALVE SEAT PULLING

The following precautions must be observed by opera-tors and maintenance personnel to avoid personal inju-ry, death and/or equipment damage from contact withthe puller, hammer, wedge or broken parts from thesecomponents when using either a hydraulic or wedgevalve seat puller. Operators or maintenance personnelshould:

Hydraulic Puller

Wear safety shoes and goggles. Chain or tie the jack down as it will jump violently

when the valve seat disengages from the valvedeck.

Check to insure the pressure applied by the hy-draulic pump does not exceed the hydraulicram maximum pressure rating.

Wedge Puller

Grind off any mushroomed material from thewedge before use.

Inspect the hammer and wedge to insure theyare in good condition. Replace any of thoseparts which are cracked, damaged or badlyworn.

Wear safety shoes and goggles. Check to insure they have safe footing. Fully engage the wedge to prevent it from dis-

engaging violently from the cover as a blow isstruck.

Wipe their hands and the hammer handle andmaintain a firm grip on the handle to avoid los-ing control of the hammer while swinging andstriking.

Carefully swing the hammer to avoid strikingthemselves, another person and objects otherthan the targeted wedge.

Avoid swinging the hammer above shoulderheight.

COVERS AND GUARDS

Personal injury, death, and/or equip-ment damage can result from contactwith moving parts. All moving partsmust be equipped with covers andguards. All covers and guards mustbe securely positioned at all timeswhen the unit is in operation.

Covers and guards are intended to not only protectagainst personal injury or death, but to also protect theequipment from foreign object damage.

EQUIPMENT MOVING AND LIFTING

Heavy equipment including pumps, pump packageunits and components should only be moved or liftedby trained, experienced operators, who are physicallyand mentally prepared to devote full attention and alert-ness to the moving and lifting operations. An operatorshould be fully aware of the use, capabilities, andcondition of both the equipment being moved and theequipment being used to move it.

Failure to follow safe and properpump, pump package or componentlifting or moving procedures can leadto personal injury, death and/orequipment damage from shifting, fal-ling or other unexpected or uncon-trolled equipment movements.

Make sure the hoist, lift truck, ropes, slings, spreader,or other lifting equipment you are using is in good condi-tion and has a rated lifting capacity equal to or greaterthan the weight being lifted. Lifting devices must bechecked frequently for condition and continued confor-mance to rated load capacity. They should then betagged with the inspected capacity together with thedate of inspection.

31606 Page 3

Fully assembled pumps and pump package units areheavy and should only be moved using the specifiedlifting lugs or attachments.

Many individual components have lifting eyes orlugs which must not be used to lift assemblies, asthey are designed to bear the weight of the compo-nent only.

Before lifting the individual component check to insurethe lifting attachment is firmly secured to the compo-nent with undamaged, properly torqued fasteners,sound welds, or other secure attachments. Examinethe lifting eyes, lugs, slots, holes or other projections toinsure they are not cracked, otherwise damaged orbadly worn. The repair of existing or addition of newwelded lifting eyes, lugs or other projections shouldonly be performed by experienced, qualified welders.

Package units should be lifted with spreaders con-nected to the lifting attachments normally built into thepackage unit support skid. Packages too large to lift ful-ly assembled should be separated into smaller loads.

For these smaller loads the lifting devices should befastened to the lifting attachments normally built intothe individual motor, engine, pump or transmission/torque converter, or their separate support skids.

When lifting subassembled components, for examplea suction stabilizer attached to suction piping or a dis-charge pulsation dampener attached to a strainer crossand piping, use special lifting slings designed to safelysupport the combined weight of the components.

If a crane or hoist is being used to lift large componentsor assemblies, one or more persons should assist theoperator from the ground with guide lines attached tothe equipment being moved to properly position it andprevent uncontrolled movement.

When you start to lift a pump, package unit, subassem-blies or individual components and you observe theequipment is tilting, or appears unbalanced, lower theequipment and adjust the lifting device to eliminatethese improper lifting conditions before proceeding tomove the equipment.

It is poor practice and dangerous to allow the equip-ment to pass over or close to your body or limbs. Beprepared to move quickly out of danger if equipmentstarts to fall, slip or move unexpectedly toward you.

PRESSURIZED PUMP SYSTEMS

Fluids under high pressure can pos-sess sufficient energy to cause per-sonal injury, death and/or equipmentdamage either through direct contactwith escaping fluid streams or by con-tact with loose objects the pressur-ized fluid propels.

Operating a pump against a blocked or restricted dis-charge line can produce excessive pressures in the en-tire discharge system, which can damage or burst dis-charge system components.

Never operate a pump without a prop-erly sized pressure relief valve lo-cated in the flowing discharge line im-mediately adjacent to the pump dis-charge connection.

The relief valve should be placed in the flowing dis-charge line and not at the opposite end of the dischargemanifold in a dead end connection. The dead end maybecome clogged with solid material carried in the fluid,which could prevent proper relief valve operation.

Never place a shutoff valve or anyother component between the pumpdischarge connection and the pres-sure relief valve.

Make sure the pressure relief valve is installed so anypressurized relief discharge from the valve is directedaway from possible contact with people or equipment.The relief valve must be set to relieve at a pressureequal to or below the maximum pressure values shownon the pump data plate. However, if a component isused in the discharge system with a lower rated pres-sure capability than that listed on the pump data plate,

31606 Page 4

the pressure relief valve must be set to relieve at a pres-sure equal to or below the rated capability of the lowestrated component.

Before starting the pump every time, check to in-sure:

The pressure relief valve is in good operatingcondition and has been set to the proper reliefpressure.

Any pipe line used to direct pressurized reliefflow to another location, such as a collectingtank, is not blocked.

The discharge system is not blocked and all thedischarge line valves are open.

Check all fluid end discharge system componentsincluding pipe, connections, elbows, threads, fas-teners, hoses, etc., at least once every six monthsto confirm their structural adequacy. With time,wear, corrosion and fatigue can reduce the strength ofall components. Magnetic iron and steel componentsshould be checked with magnetic particle or dye pene-trate crack detection equipment. Nonmagnetic materi-als should be checked for cracks with dye penetrants.All metallic components should also be visuallychecked during these inspections for signs of corro-sion. If a component shows evidence of cracking orloss of material due to corrosion it must be replacedwith a new part.

Continually monitor suction and discharge hose as-semblies when the pump is operating for leakage, kink-ing, abrasion, corrosion or any other signs of wear ordamage.

Worn or damaged hose assemblies should be re-placed immediately. At least every six months ex-amine hose assemblies internally for cut or bulgedtube, obstructions and cleanliness. For segment stylefittings, be sure that the hose butts up against the nippleshoulder, the band and retaining ring are properly setand tight and the segments are properly spaced.Check for proper gap between nut and socket or hexand socket. Nuts should swivel freely. Check the lay-line of the hose to be sure that the assembly is nottwisted. Cap the ends of the hose with plastic coversto keep them clean until they are tested or reinstalledon the pump unit. Following this visual examination,the hose assembly should be hydrostatically tested, ontest stands having adequate guards to protect the oper-ator, per the hose manufacturers proof test procedure.

Fluid end component inspections should be per-formed more frequently than every six months ifpressures above 2500 psi are used in the dis-charge system or if corrosive, flammable or hot(over 110 F) fluids are being pumped.

Proper stuffing box packing selection is important forsafe pump operation. Contact a Gardner Denver Ma-chinery service representative for assistance in select-ing the proper packing before beginning operation.Before starting the pump the first time and periodicallythereafter check the pump, suction and discharge sys-tem fastener torques versus the values listed on page12 to insure proper tightness. Over and under torquingcan damage threaded pipes, connections and fasten-ers, which may lead to component damage and/or fail-ure. Replace all components found to be damaged ordefective. On pumps equipped with stuffing boxes, thegland must be engaged by at least three (3) threads tohold the discharge pressure of the pump.

Do not attempt to service, repair, ad-just the plunger packing or otherwisework on the pump while the unit is op-erating. Shut off the pump drive mo-tor or engine and relieve the fluidpressure in the pump suction and dis-charge systems before any work orinvestigation is performed on thepump or pump systems.

Block the crankshaft from turning and make certain thatall pump drive motor or engine start switches or startercontrols are clearly tagged with warnings not to startthe pump while repair work is in process.Whenever the pump is operating, continually monitorthe entire suction, discharge and pump lubricating sys-tems for leaks. Thoroughly investigate the cause forleakage and do not operate the pump until the causeof the leak has been corrected. Replace any partswhich are found to be damaged or defective. When agasketed joint is disassembled for any reason, discardthe used gasket and replace it with a new, genuine Gar-dner Denver gasket before reassembling the joint.Due to the high working pressures contained by thefluid cylinder, discharge manifold and discharge piping,welding on these components is not recommended. Ifwelding on the discharge system cannot be avoided,only experienced, qualified welders should be used. Inaddition, the welded part should be hydrostaticallyproof tested in the shop with water or hydraulic fluid toone and one half times maximum discharge systemworking pressure, with no observable fluid leakage, be-fore the part is reinstalled in the pump system.In summary, high pressure fluid streams can possess

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sufficient energy to cause personal injury, death and/orequipment damage. These results can occur eitherthrough direct contact with the fluid stream or by con-tact with loose objects the fluid stream has propelled,if the pump system is improperly used, or if the fluid ismisdirected, or allowed to escape from defective or im-properly maintained equipment.

FLAMMABLE, HOT, COLD OR CORROSIVE FLUIDPUMPING

Extreme caution must be exercisedby trained and experienced operatorswhen flammable, hot, cold or corro-sive fluids are being pumped, in orderto avoid personal injury, death and/orequipment damage due to explosion,fire, burn, extreme cold or chemicalattack.

Never operate a pump which is pumping hydrocarbonsor other flammable, hot, cold, or corrosive fluids whenany part of the pump, suction system or discharge sys-tem is leaking. Stop the pump immediately if any leak-age, other than a few drops per minute of packingweepage, is observed. Keep all flame, sparks, or hotobjects away from any part of the pump, suction sys-tem, or discharge system. Shield the pump, suctionsystem and discharge system to prevent any flam-mable, hot, cold or corrosive fluid leakage from drippingor spraying on any components, flame, sparks, hot ob-jects or people. Inspect the plungers, packing, gasketsand seals for fluid leakage frequently and replace allworn or leaking parts.

Selection of the proper gaskets, seals and stuffing boxpacking is even more critical when flammable, hot, coldor corrosive fluids are being pumped than when other,inherently less dangerous fluids are used. Contact aGardner Denver Machinery service representative forassistance in selecting the proper gaskets, seals andpacking before beginning operation.

Since some packing weepage into the cradle area is in-evitable, the drain at the bottom of the cradle must beconnected to a drain line which conducts the fluid leak-age to a collection container located in a protectedarea. The entire drain system and container must beconstructed of materials resistant to attack from thepumped fluid or from explosion or fire of the pumpedfluid. Heavy duty cradle covers must be securelyfastened in the proper position on the pump at all

times when the pump is operating. If the pumpedfluid releases harmful, explosive or flammable va-pors the covers must be vented to conduct thefumes away from the pump unit to a nonhazardousarea.

Before beginning pumping operations or starting thepump power source (whether an engine or electric mo-tor) check the atmosphere all around the pumping sitefor the presence of flammable or explosive vapors. Donot begin operation and stop ongoing operation if flam-mable or explosive vapors are detected. Hot surfaces,sparks, electric current or engine exhaust could igniteflammable or explosive vapors. Each engine used asa power source on pumping units where flammable orexplosive vapors could form should be equipped withan air inlet shutoff. If flammable or explosive vaporsare present in the pumping site atmosphere, an enginecould continue to run on these vapors even after the en-gine fuel line is shutoff if an air inlet shutoff is notused.

In addition, on pumping units used where flammable orexplosive vapors could form, all electric motors used aspower sources must be of explosion proof constructionand all electrical components and wiring must meet thecurrent National Electrical Code for explosive atmosp-heres.

These precautions must be taken to avoid possible per-sonal injury, death and/or equipment damage from ex-plosion, fire or burns.

HIGH PRESSURE LIQUID JETTING, BLASTINGAND CLEANING

Extreme caution must be exercised ifany type of wand, gun, nozzle or anyother pressure and flow directing de-vice is attached to the pump dis-charge system for use in jetting,blasting, cleaning, etc. This type ofequipment must be used with utmostcare by trained, experienced opera-tors. High pressure fluid streams caneither by direct contact or by propel-ling loose objects, cause serious per-sonal injury or death to the operatorsand/or other persons.

Pressure or flow directing devices often receive pres-surized flow through flexible hoses, which can burst if

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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 bursthose can release pressurized fluid which may causepersonal injury, death and/or equipment damage.High pressure fluid from hand held or hand directedpressure and flow directing devices may overpower anoperators ability to control or direct the device, whichcould lead to personal injury, death and/or equipmentdamage. The operator must brace against the back-ward thrust of a hand held device. In addition, a safetyharness or safety net must be used when working in anarea where the operator could be injured in a fall. Standto the side of any tubing or container being sprayed toavoid back spray and never operate a hand held deviceabove shoulder level.

Never direct the pressurized fluid stream at yourself orany other person, control valves, the pump, pumpdrive, suction or discharge systems. The pressurizedstream can cause serious personal injury or death andcan also change valve or control settings which coulddangerously increase the delivery pressure to the pres-sure and flow directing device.

When operating a pressure and flow directing device,use only equipment which automatically shuts off flowwhen an operator releases hand or foot pressure on thepressurized flow trigger control to prevent injury if theoperator is overpowered or becomes disabled.

Check to insure this automatic shutoff equipment isoperating properly before every use and never circum-vent the automatic shutoff for any reason or by anymeans when operating the equipment.

When operating any type of high pressure liquid jetting,blasting or cleaning devices the operators must alwayswear protective clothing including, but not limited to, ahard hat with full face visor, heavy duty rain coat andpants, boots with nonskid sole and safety toe, rubbergloves with rough grip surface and ear noise protection.

Full operator attention and alertness are required whenoperating this equipment to avoid personal injury, deathand/or equipment damage. The operators should takefrequent rest breaks and cease operations when theybecome tired or distracted.

Before the equipment is started, the work area must beinspected and properly prepared to avoid personal inju-ry, death and/or damage to equipment. Make sure thework area is checked for hazardous fumes, has ade-quate ventilation for engine exhaust and sufficientdrainage for released fluid. Check the work area forelectrical equipment, connections, outlets, fixtures, orlines. If any are present they must be made water tight

and the electrical power to these devices must be shutoff to avoid electrical shocks from fluid contact. Thework area should be clearly marked and roped off tokeep unauthorized people and vehicles from entering.Remove all loose parts, tools and equipment from thework area before beginning operation.All pressure containing devices including wands,nozzles, guns, hoses, connections, etc., should be reg-ularly checked for condition. These componentsshould all be tagged with their tested pressure capabili-ties together with the date testing was performed. Al-ways be aware of the pressure level in the systemand never connect any equipment to the systemwhich has a rated or tested pressure capability be-low the system operating pressure. The equipmentmust be shut down and the system pressure releasedbefore changing or disconnecting wands, nozzles,guns, hoses, connections or any other pressurizedsystem components.

All pressure containing devices including wands,nozzles, guns, connections, etc., plus all automaticshutoff, pressure and control equipment should betreated with care. Protect them from damage bypeople, objects and vehicles. Never lay them in dirt,mud, ice or other loose material which could plug thefluid opening or interfere with their operation. Neveruse the wand, nozzle, gun, etc. to pry loose material offitems being cleaned.Before starting operation in a cold environment, checkto make sure there is no ice in the fluid system and re-peat this inspection each time before operation is re-started.

Before purchasing wands, nozzles, guns, connections,and hose, etc., manufacturers of these componentsshould be contacted for detailed information on the de-sign and safety features incorporated in their products.After careful study of various manufacturers products,we recommend that only those wands, nozzles, guns,connections and hose, etc., be considered for pur-chase that you judge to offer the highest quality of de-sign, construction and safety, since these componentsare among the most critical to the safe operation of highpressure liquid jetting, blasting and cleaning equip-ment.

After you have selected and purchased these compo-nents, follow the manufacturers instructions complete-ly in their use.

In summary, high pressure jetting, blasting andcleaning are inherently dangerous, as the pressur-es and flow rates needed to remove scale, clean,etc. are sufficient to cause personal injury, deathand/or equipment damage resulting from, but notlimited to, any of the conditions described in theabove Danger Notices.

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FIGURE 1 SECTIONAL VIEW OF TEE TRIPLEX PLUNGER PUMP

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SECTION 2OPERATING AND MAINTENANCE INSTRUCTIONS

INSTALLATION

Always wear safety shoes andgoggles when operating and perform-ing maintenance or repair on a pumpor pump package unit to help preventpersonal injury to eyes and toes frompressurized fluids and falling or flyingobjects.

LOCATION Pump should be located as close to thefluid supply as possible. A short and direct suction linewill improve pump performance and reduces the possi-bilities of cavitation. Whenever possible, adequatespace should be provided around the pump to permiteasy inspection and adjustment. Particular attentionshould be given to the space required for removal andinstallation of the gear reducer, eccentric, packing, etc.

The drive must be accurately aligned. Pump must beproperly leveled and securely fastened to a foundationor base. The pump must have a positive suction head.Refer to page 24 for NPSH requirements. Maximum al-lowable temperature of the fluid being pumped is 200F (93 C). The maximum allowable suction pressure is150 psi. Any application with suction pressures over 50psi must be approved in writing by Gardner Denver Ma-chinery Inc. Engineering Department.

SUCTION PIPING Suction pipe (or hose if used)should be the full size of suction opening. If, for any rea-son, the suction line is of greater length than usual, thenext larger size should be used. Suction line shouldslope up towards the pump at a uniform grade so thatair pockets are eliminated. Suction line must be air tightas any air leaking into the line will reduce the volumetricefficiency of the pump. If it is necessary to have bendsin the suction line, they should have long radiussweeps.

Refer to page 23 for recommended suction piping sys-tem.

All piping must be supported independently of the pumpto insure that no strain is imposed in the pump by mis-alignment or improperly fitted pipe.

The suction line strainer must beserviced at regular intervals. Aclogged or partially clogged strainercan cause severe pump cavitation,poor expendable part life and poten-tially serious pump damage.

PRESSURE RELIEF VALVE The pump must be pro-tected from excessive discharge pressure by a pres-sure relief valve. This valve must be installed as nearpump discharge as possible.

Never install a shutoff valve in the linebetween the pressure relief valve andthe pump cylinder, as pumpingagainst a closed valve could producepressures sufficient to cause proper-ty damage and/or serious personal in-jury or death.

Improper use or maintenance of pres-sure relief valves can cause exces-sive pressure which may result inproperty damage and/or serious per-sonal injury or death.

The pressure relief valve should be set to operate atapproximately 1.1 to 1.25 times the discharge pressure,depending on the relief valve manufacturers recom-mendations, but this setting MUST NOT exceed adjoin-ing system equipment rated pressure capabilities. Therelief valve must be sized to accept the full pump flowper the valve manufacturers instructions. When thepump is equipped with a shear pin type pressure relief

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FIGURE 2 AUXILIARY OIL PUMP DIAGRAM

valve, use only the shear pin specified in the relief valvemanufacturers instructions. Do not use allen wrenchesfor shear pins, or hammer on the shear bar stem, orshear bar slot. For complete installation and mainte-nance instructions refer to the relief valve manufactur-ers catalog and/or instruction manual.

LUBRICATION POWER END Use only extremepressure GL5 gear oil in the crankcase. The crank-case oil capacity is 12 gallons (45.5 liters). Add oil as re-quired to keep oil level with top of pipe elbow located onthe side of the pump frame. Never use motor oils in thecrankcase as they do not provide acceptable lubrica-tion.

Use only extreme pressure, API GL5gear oil, having the required additivesand viscosity, in the crankcase. Theuse of motor oils in the crankcasedoes not provide acceptable lubrica-tion and voids the warranty.

The selected API GL5 oil must have antiwear, anti-foaming, noncorrosive and rust inhibiting additives. Alist of recommended grades vs. temperatures is locatedat the back of this manual and on the pump lubricationdata plate. The list is based on premium quality oils hav-ing viscosity values that do not exceed 7000 SSU at theminimum startup oil temperatures listed and viscosityvalues between 1500 SSU and 200 SSU for crankcaseoil temperatures listed. Oils with viscosity values signifi-

cantly different from these values, at the temperatureslisted, may be too thick at low temperatures to flow intoclose bearing clearances, or may be too thin at hightemperatures to carry the required loads. In either casepump damage could occur.

If a 7000 SSU maximum viscosity at startup cannot beassured, a crankcase heater is required. Also if crank-case oil temperatures exceed 200 F (93 C), an oilheat exchanger with a circulating pump is required toprevent seal damage and oil break down.

For outdoor operation, the multiviscosity oils are pre-ferred to provide acceptable lubrication over wide tem-perature ranges. However, when multiviscosity oils arenot available, straight weight oils should be acceptable,if care is taken to stay within the listed temperatureranges. Straight weight oils are also ideal in pumpsused indoors, when ambient temperatures are con-trolled.

The oil level in the pump should be checked frequently.Add oil through the breather opening. The breather canbe removed by rotating and lifting. Keep the breathertightly in place while the pump is operating to preventmoisture and dirt from entering the crankcase. Onpumps equipped with a replaceable filter element typebreather, clean the element frequently and replace theelement every six months. When operating in verydusty or dirty conditions, more frequent replacementmay be necessary.

If the pump has been stored or shut down for an ex-tended period, the crankcase should be drained andfilled with new oil before startup.

Pump lubrication is provided by a forcefeed system.The oil pump is rotary type, driven off the main shaftwhich delivers filtered oil to the connecting rod linersand crosshead pin bushings. The oil pump is reversibleand will operate in either direction.

When the pump is on intermittent (well service) opera-tion and speed is below 100 RPM, an auxiliary oil pumpis required to maintain lubrication to the main bearingsand crossheads, as shown in FIGURE 2.

The auxiliary oil pump must have a capacity of 10 gal-lons per minute.

Do not operate TEE Well ServicingPump below 50 RPM.

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FIGURE 3 HEAT EXCHANGER ASSEMBLY

Customer to Remove Existing LineBetween Oil Filter and Lube Pump

3/4 in. Dia. Hyd. HoseFurnished by Customer

1/2 in. Dia. Hyd.Hose AsmFurnished by Customer

Bushing

OilFilter

Bushing

Heat Exchanger

BushingBushing

TemperatureValve

Lube Pump

Discharge

NOTE: Refer to Parts List for Gardner Denver Part Numbers.

C76898

A minimum oil pressure of 25 psig(1.725 bar) and oil viscosity of 200 ssumust be maintained at all times. Fail-ure to observe this warning could re-sult in severe pump damage from lackof adequate lubrication and voids theWarranty.

The pump can be driven in either direction. The pre-ferred direction of rotation of the input shaft is indicatedby an arrow located on the frame.

The indicated direction is recommended becausecrosshead load will be carried on the bottom guide, re-sulting in a more quiet operation and better lubrication.

Well servicing pumps must be drivenonly in the direction indicated on theframe to provide adequate lubricationand prevent excessive pump wear.

OIL FILTER A replaceable element oil filter is locatedoutside the crankcase. Filter element should be re-placed each time the crankcase oil is changed or every1000 hours.The oil filter and all other oil pump system componentsare protected from excessive internal oil pressure by apressure relief valve between it and the oil pump. Thepressure relief valve setting is 75 PSIG (5.175 bar).Time between oil changes depends upon local or oper-ating conditions. Ordinarily, if the crankcase is keptclosed, it should not be necessary to change oil more

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often than once in 1000 working hours. However, theoil must be changed anytime water or other contamina-tion is found. The oil pressure gauge and oil level gaugemust be checked frequently and if the pressure is lessthan 25 PSIG, the oil level must be checked.

The oil should be checked for con-tamination whenever pumped fluidsprays or splashes against an oil stophead. This is especially critical whenthe fluid contains salts or solids, asthese contaminants can plug lubri-cating passages and cause rapidpower end failure.

The screen on suction pipe might be stopped up so thatthe pump cannot get sufficient oil to maintain pressure.This screen should be examined when the oil ischanged and cleaned thoroughly. The oil should bechanged if found to be dirty or if it contains any contami-nation or water.

Pumps are shipped from the factorywithout oil in the crankcase.

HEAT EXCHANGER (Optional Equipment) Abronze shell and tube heat exchanger can be providedto keep crankcase oil temperature at 160 F (71 C) byusing an automatic water control valve. This valve hasa heat sensing probe in the crankcase oil which controlswater to the heat exchanger to maintain oil temperaturewithin limits. See FIGURE 3, page 10.

STARTING A NEW PUMP The hood should be re-moved, power end examined and cleaned if necessary.Pump may have been in storage or in the yard for sometime and as a consequence, dirt or rust from condensa-tion may have formed in the crankcase. Drain all wateraccumulation from the bottom of crankcase. Check allnuts and screws and tighten if necessary. Fill crank-case with oil of proper grade to proper level. Quantityon the data plate indicates the approximate oil require-ment.

Priming is important! it lubricatesplungers or pistons and liners. Ifthese parts are not lubricated theycould be severely damaged in opera-tion.

To prevent excessive wear on fluid pistons or plungersand packing when starting, remove the discharge valvecover plates and discharge valves and prime the pump.The pump should be started slowly and operated forseveral hours with little or no discharge pressure.

Check the oil level as it may be necessary to add a smallamount of oil to compensate for that adhering to wallsof the crankcase and moving parts.

The pump may then gradually be brought up to fullspeed and full working pressure. Watch for undue heat-ing or abnormal noise in the working parts. Check alljoints in the suction line to be sure there are no air orfluid leaks. Check for abnormal vibration caused by im-proper suction conditions. Be sure stuffing box pack-ings are properly lubricated.

Before starting a pump which has been idle for a longperiod of time, drain any water accumulation fromcrankcase by removing the drain plug and replacingwhen clean oil begins to flow from the drain. Add oil toproper level. It is recommended that the fluid end ofpump be primed to prevent excessive wear on theplungers or pistons and liners when starting.

OPERATION Pump should always be started slowly,with little discharge pressure; this gives oil a chance towarm up and flow through all oil lines and bearings. Thiswarmup is especially important during cold weatheroperation.

The frame cradle safety cover, allguards and all inspection plates mustbe securely fastened in proper posi-tion before the pump is started andnot removed while in operation toavoid personal injury and/or deathfrom moving parts.

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Pump must never be operated atspeeds or pressures exceeding thevalues shown on the nameplate. Nev-er operate pump below 50 rpm on in-termittent service or 100 rpm on con-tinuous service without written ap-proval from Gardner Denver Machin-ery Inc. Failure to observe this warn-ing could result in severe pump dam-age due to overloading and/or lack ofadequate lubrication.

The pump must not be operated at speeds exceedingrated speed on nameplate. Horsepower given in bulle-tin must not be exceeded. Application approval must beobtained from Gardner Denver Machinery MarketingDepartment for any application in which pump speed isbelow 50 RPM.SERVICE INSTRUCTIONS FLUID END

FLUID CYLINDERS (FIGURE 4) The aluminumbronze fluid end is a onepiece casting. The gasketsat the joints between valve covers and stuffing boxesare the rubber ring type. These gaskets must beinstalled with the chamfer facing up. The gaskets mustbe installed in their grooves carefully and the part tight-ened up squarely and evenly to prevent pinching thegasket and to insure a tight joint.Aluminum bronze fluid ends are built in two (2) differentsizes. The low pressure fluid end uses 4 inch (10.16cm) diameter master size plungers. The medium pres-sure fluid end uses 3 inch (7.62 cm) diameter mastersize plungers.

Block steel fluid cylinders are threepiece forged steelwith bolted on suction and discharge manifolds.

The cast steel fluid cylinder is onepiece with bolted onsuction manifold.

All pumps have separate stuffing boxes which can beremoved to service or replace with other sizes to ac-commodate plungers of other available diameters.

Block steel and cast steel well servicing fluid cylindersare also available with piston and liner construction.

Fluid cylinders are secured to the frame by high tensilestrength connecting studs. It is important that nuts on

FIGURE 4 SECTIONAL VIEW OF TYPICALFLUID CYLINDER

these studs be checked occasionally for tightness. Aloose or improperly torqued nut will cause a stud tobreak under a pulsating load. For proper tighteningtorques refer to pages 32 and 33.TAPERED SEAT VALVES This type of valve is re-tained in the cylinder by the locking action of the match-ing valve seat and deck tapers.The valves should be examined regularly for excessivewear and for coating or particle adhesion that may pre-vent proper valve opening and closing. A valve that isnot sealing, opening and closing properly, or a seat thatis improperly seated in the deck, can fail quickly by ero-sion of the valve, seat or deck.Access to the discharge valves is gained by removingthe valve covers on top of the cylinder. The valve cov-ers are held in place by studs and nuts. The retainersor cages, springs and discs or valves must be removedbefore the seats can be inspected or pulled. On fluidcylinders without front suction valve covers the suctionvalves can be examined after the discharge valve seatshave been removed with a valve seat puller. The suc-tion valve seats are also removed with a valve seat pull-er.

The outside diameters of the suction valve seats on allcylinders without suction valve covers are smaller thanthose on the discharge valves, to enable the suction

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valves to be installed and removed through the dis-charge valve decks. However, where the suction valvecovers are used, the suction and discharge valves mayuse the same size seats.Several different valve options are offered for the pumpmodels covered by this manual. Consult Gardner Den-ver Machinery Marketing Department or your nearestsalesman if you need help deciding which valves to use.DISC VALVES This style of valve, made of either alu-minum bronze or stainless steel, is used as standardequipment in low and medium pressure tapered seatdeck fluid cylinders. Model valves are also available forfluids that attack aluminum bronze and stainless steel.Delrin (or Celcon) discs are recommended for waterand most clean fluids up to 160 F (71 C). Titaniumdiscs are specified for fluids with higher temperatures,trace amounts of abrasives and with fluids that attackDelrin (but not titanium) discs.The valve plate, springs and retainer are secured by afastener that passes through these parts and threadsinto the seat. These parts can all be lifted out and in-spected by removing the fastener. The seat should beremoved, using the properly sized puller assemblyshown in the pump parts list manual. Puller kits can bepurchased as optional equipment from Gardner DenverMachinery Inc.Note that two different types of puller heads are used toremove disc style valve seats. For larger seats, aslotted finger design head slips down through the seatopenings and is then rotated to engage the seat ribs.For smaller seats, the seat openings are not largeenough to use this design puller head. The smaller seatpuller heads have a center threaded bolt and stud whichscrews into the threaded center hole in the seat.

Wear eye protection when removingthe valve seat as metal chips could bedislodged from the valve seat or valvepuller and fly up into your face.

When preparing to remove a valve seat, tightly as-semble the proper finger or threaded design puller headon the smaller thread end of the puller rod. Insert thepuller head and rod into the valve cover opening on thetop of the cylinder and either engage the puller fingersin the seat or tightly thread the head into the seat. Slipthe puller plate onto the puller rod using the center holein the plate. Lower and rotate the plate until the studsline up with the holes in the puller plate. Continue lower-

ing the plate over the studs until the plate rests on topof the cylinder. Place the stepped washer (stepped sideup) over the puller rod and drop it down on the plate.Put the flat washer and then puller nut on the puller rod.Push the puller wedge between the stepped and flatwashers with the two wedge legs straddling the pullerrod and with the outer edge of one leg against the stepon the stepped washer.Continue pushing the wedge between the washers untilthe wedge leg tips reach the opposite edges of the twowashers. Holding the wedge in this position, firmlytighten the puller nut with a properly sized wrench. Theseat can then be pulled by striking the stem end of thewedge with a heavy hammer. This type of puller usesa combination of pull and impact to disengage the seatfrom the cylinder deck taper.Do not use a hydraulic jack type puller with a disc valveseat that has a small threaded hole in the center usedfor both the retaining screw and seat pulling. The verystrong, steady pull produced by a hydraulic puller ismore likely to break the puller faster than is the com-bination pull and impact the wedge puller provides.A new valve as taken from the carton should be cleanedthoroughly with solvent and wiped dry with a clean cloth.Check the tapered surface to be sure it has not been ac-cidentally nicked or dented in handling. The valve as-sembly should be disassembled by removing the singlefastener; be careful not to lose the small nylon threadlock plug.

Never attempt to install the valves asan assembly. The valve could bedamaged when a block and hammerare used to strike the retainer to setthe seat.

Wipe the taper surface of the seat and pump port taperwith a clean cloth. Lower the seat into the port taper andthen lift slightly and drop. If the seat drops straight, itwill seize on the taper sufficiently that it cannot be pulledup by hand. It is necessary to strike the seat once toassure a perfect seat. This may be done with a shortsection of hard wood and a fourpound (1.8 kilogram)hammer. The end of the wood block placed against thevalve seat should be large enough to cover the outersealing ring. One sharp blow should be sufficient forproper seating. Additional hits may jar the seat looseand could damage the seat. Check the seat top surfaceto see that it has not been damaged after the seat hasbeen installed.

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After all suction valve seats have been installed, placethe valve plates, springs and retainers in place, then se-cure with the retainer bolt. Carefully position the valveplate and retainer, so as not to pinch the plate closed ordamage the guide while tightening the fastener. Torquethe retainer bolt to the value shown on page 33. If theseat comes loose from the taper when the disc, springand fastener are being installed, the valve must be dis-assembled before striking the seat again.

It is possible to lock a valve closed byeither mispositioning the retainerstem on top of the valve plate whenthe retainer bolt is tightened, or byovertightening the retainer bolt andexpanding the retainer stem until itcontacts the disc bore.

After all suction valves are in place, the dischargevalves are installed in the same manner. Install thevalve covers and gaskets. Tighten the cover stud nutsto the torque listed on page 33.WING GUIDED AND SEVERE DUTY VALVES These valves are used in high pressure, tapered seatdeck cylinders where pressures are too high for discstyle valves. They are also used in low and mediumpressure cylinders, where disc valves cannot toleratefluids with high temperatures, abrasives or chemicalsthat attack the discs. Some of the wing guided and se-vere duty valves are offered with urethane insert op-tions to handle high abrasive concentrations. However,the inserts will not hold up in fluids with temperaturesabove 160 F (71 C) or in fluids that attack urethane.These valves are retained by a cage that screws ontothe seat. A valve cage removal tool can be purchasedfrom Gardner Denver Machinery Inc. Refer to the PartsList for the part number.The wing guided valves can be removed with one of twotypes of puller heads, threaded on the puller rod. Thefirst type head uses the retainer attaching threads onthe top of the valve seat. Since only a few threads arerequired (and provided) to hold the cage to the seat,these threads can be easily damaged by a puller headif the seat is hard to pull. Therefore, a hydraulic jackseat puller is not recommended for use with this stylepuller head.The second type of puller uses a cam arrangement topass through the seat opening and engage one side ofthe seat bottom. This type head is preferred since it is

less likely to damage the seat during the puling proce-dure. When using either type of puller head, follow thevalve pulling procedure outlined in the disc valve sec-tion, page 13. The second type of puller head can beused with a hydraulic jack type puller.

If a seat puller powered by a hydraulicjack is used, be certain to chain or tiethe jack down as it will jump violentlywhen the valve seat lets go.

The severe duty, tapered seat valves can be removedwith a threaded puller head. This type puller head hasthreads on the outside diameter that match the threadscut into the inside diameter of the seat. When using thistype of puller head, follow the valve pulling proceduredescribed in the disc valve section , page 13. A hydrau-lic jack type puller can be used with this type head.Before installing a valve, make sure the seats and decktapers are clean and dry. Inspect both seats and decktapers to insure they re not scratched, nicked or other-wise damaged. Replace any seat found damaged andhave any damaged deck tapers remachined. Do notcoat the tapers with any kind of lubricant or coating be-fore assembly.

Never attempt to install wing guidedvalves as assemblies as the valvecage will be damaged.

Drive the seat into the taper using a fourpound (1.8kilogram) hammer striking either a wood block (cover-ing the full upper surface of the seat) or one of the facto-ry option valve seat drivers that thread onto the variousstyle valve seats. One sharp blow on the block or therod end of the driver should be sufficient for seating. Ifthe seat jumps up when it is struck, take it out and in-spect both the seat and the deck tapers. They must beclean, dry and undamaged before a second attempt ismade to install the seat. Again use only one sharp blowon the block or driver after dropping the seat into the ta-per. Excessive pounding could loosen or damage theseat.Use caution when installing the valve cover to preventpinching of gaskets. The gasket must be installed withthe chamfer facing up. Tighten the valve cover nuts toproper torque as shown in Rebuilding Data, page 32.

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STUFFING BOXES Stuffing boxes made from differ-ent materials and in several sizes can be matched withvarious fluid cylinders used on the pumps.When servicing a stuffing box, plunger or packing, startby removing the plunger to extension rod coupling.Keep the coupling halves together as sets. Do not inter-mix halves.

After removing the plunger to cross-head extension coupling, do not usea screwdriver or cold chisel to sepa-rate the extension and plungerflanges, as burrs may be formedwhich could cause misalignment onreassembly. Instead, rotate the ec-centric slightly. If the parts do notseparate, carefully slip a pipe wrencharound the plunger neck and use apulling and rotating motion to sepa-rate the plunger from the extensionrod. Use caution to avoid damagingthe plunger wear surface.

Continue to rotate the crankshaft to pull the extensionrod away from the plunger as far as it will go. Removethe gland nut and the stuffing box stud nuts. Lift thestuffing box, plunger and packing assembly out throughthe cradle opening in the top of the pump frame. Laythe stuffing box assembly on a work bench and slide theplunger and packing out of the stuffing box.When replacing the stuffing box, plunger and packingassembly, the above procedure is reversed. However,first inspect the stuffing box bore for scratches, wear orother defects. Clean and check the stuffing box face,gasket groove and outside diameter that pilots into theframe, to insure they are free of defects, burrs and dirt.Clean out any burrs, dirt and rust in the stuffing box pilotbores in the frame. Install the packing in the box. Placea new gasket in the stuffing box groove. The gasketchamfered edge must face out to prevent gasket pinch-ing when the stuffing box and cylinder surfaces arepressed together. Place the stuffing box assembly onthe stuffing box studs.If the stuffing box does not enter the frame easily, do nothit the box with any type of hammer, as you may dam-age the box or dislodge the gasket from the groove.Instead, remove the box and recheck the frame bore fordirt or rust buildup and the stuffing box pilot for dirt or

damage. Install and torque the stuffing box stud nutsto the value listed on page 32. Alternately tighten thenuts diagonally across from each other to insure thegasket is drawn up evenly. Install the gland bushing andgland on the box.

PLUNGERS Plungers with Colmonoy, ceramic ortungsten carbide wear surfaces are normally used, de-pending on the service conditions. However, other ma-terials can be supplied for special applications.

To remove a plunger, remove the coupling which holdsthe plunger to the crosshead extension.Remove the four (4) nuts holding the stuffing box toframe studs and lift the plunger and stuffing box assem-bly through top opening in the frame. On some pumpsequipped with suction valve covers, the plunger can beremoved through the opening in the cylinder by takingthe cover off and shoving the plunger through the pack-ing. To assemble, reverse the above procedure.Before installing a new plunger, or reinstalling a usedplunger, check for scratches, pits, nicks or a rough fin-ish on the plunger wear surface. Inspect the mating pi-lots and ends of both the plunger and extension rod forburrs and dirt. Check to make sure the extension rodpilot is not broken or damaged. A broken pilot couldalso be lodged in the plunger pilot hole. Replace anydamaged parts. Burrs, other damage, or dirt betweenthe plunger and extension rod ends and pilots can mis-align a plunger and lead to early plunger and packingfailure.

Use only Gardner Denver replacement plungers, asmany other brands do not have the material quality orfine surface finish needed to provide long plunger andpacking life.A plunger, packing and stuffing box should be installedin the pump as an assembly (see Stuffing Boxes,above). After this assembly has been completed, takethe plunger coupling halves that had been kept as amatched set from the time of disassembly, and installthe set using the fastener torque listed on page 32. Ifone coupling half has been damaged, do not use a newhalf with a used half. Instead, use a complete new cou-pling set. Tighten the coupling evenly so the gap be-tween the halves is the same on both ends.

PLUNGER PACKING The stuffing boxes are packedwith nonadjustable lip type packing for low pressure,general service applications. Self adjusting packing invarious lip styles and braided configurations is also of-fered for higher pressure and/or special service condi-tions. Lubrication is required for all lip style and mostbraided style packings. Packing lubricating oil typesand required flow rates are discussed in Packing Lubri-cator, page 16.

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Before installing the packing, clean the stuffing box andcheck the bore for nicks, scratches and wear. A dam-aged box should be replaced to avoid early packing fail-ure. Inspect all metal and/or plastic packing rings,spacers and bushings to insure they are clean and freeof nicks and burrs. Always install new packing rings incomplete sets. Coat all packing parts with light oil. DONOT USE GREASE. Install the packing and compo-nents in the stuffing box in the same order as the partswere removed. When using lip style packing, be surethe lips of the sealing rings face the pressure (towardthe fluid end). Coat the plunger with oil and slide it intothe packing.

Install stuffing box, plunger and packing as an assemblyon the fluid cylinder, using the procedure described inthe Stuffing Boxes, page 15.

This procedure details that the glandshould not be threaded on the stuff-ing box before the box is assembledon the fluid cylinderThis assembly sequence is recom-mended, since on most pump modelsthe gland will interfere with thewrench and/or socket used to tightenthe stuffing box retaining nuts, partic-ularly nuts on the bottom side of thebox.

When the nonadjustable packing is used, tighten thegland firmly with a 24 inch section of one half inch pipeplaced over a lock pin, which has been inserted in a lockpin hole in the gland. When using selfadjusting pack-ing, tighten the gland nut firmly, after assembling it met-altometal with the stuffing box. Do not overtightenthe nut, as the threads or lock pin holes could be dam-aged.

Do not attempt to adjust packingwhile pump is in operation to avoidpersonal injury or death from movingparts.

Regardless of the packing used, thegland must be engaged by at least (3)threads to hold the pump dischargepressure. An improperly tightengland could cause personal injury,death and/or equipment damage.This can occur either through directcontact with the pressurized flow orby contact with objects the fluidstream propels.

When using the nonadjustable packing, operate thepump for two (2) or three (3) hours under pressure, stopthe pump, relieve the pressure and retighten the glandsto prevent packing movement.

Regardless of the style packing used, keep lock pins inplace to prevent the glands from backing loose.

Several other types of packing may be used in standardstuffing boxes. Installation procedures for other pack-ing may vary from the above. Additional informationcan be obtained by contacting Gardner Denver Cus-tomer Service.

PACKING LUBRICATOR A forcefeed plunger pack-ing lubricator is required for most packings and is avail-able as optional equipment. The lubricator is mountedon a bracket over the frame and is driven by a ratchetdrive off the plunger coupling. Oil is delivered to thetapped opening in each stuffing box through steel tub-ing. The lubricator is equipped with a check valve ateach stuffing box connection.

Use rock drill oil for normal conditions and steam cylin-der oil for high temperature fluids. Select an oil with theproper pour point for the ambient temperature. Someacceptable oils are listed in the chart on page 22.

Initially set the lubricator to deliver eight (8) to ten (10)drops of oil per minute to each stuffing box. More flowmay be required for large plungers and/or high speeds,pressures or pumped fluid temperatures. Less flow maybe needed for small plungers and/or low speeds orpressures. Flow can be controlled by backing off thejamb nut that locks each plunger body in position on thelubricator and rotating the plunger body. Rotate theplunger clockwise to increase flow and counter clock-wise to decrease flow. Lock the jamb nuts down againafter making an adjustment. Increase the flow if thepacking starts to heat up.

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FIGURE 5 SECTIONAL VIEW SHOWING ECCENTRIC

PISTON LINERS AND LINER CLAMPS When linersare reinstalled or replaced, check cylinder to frame studnuts and tighten if necessary. Refer to page 32 for prop-er tightening torques.Nuts holding liner clamps in place should not be over-tightened as distortion of liner clamp and liner bore mayresult. Recommended tightening torque is shown onpage 32.Change sizes of pistons and liners as volume and/orpressure requirements change.Liners are replaced by removing the liner clamps. Lin-ers should be cleaned and oiled after removal to protectagainst rusting during storage, as they can be usedagain if bore is in usable condition.Pump liners are to be clean both inside and out prior toinstallation. Also clean the liner clamp bore and lightlyoil all surfaces.Always use new gaskets when installing liners and besure to clean all surfaces against which the gaskets fit.Liners and/or fluid cylinders may be cut by leaking gas-kets. If the pistons are properly maintained, there willbe little or no cutting of the liners.PISTONS Singleacting pistons consist of a steel pis-ton body with insert retained by a washer and snap ring.Pistons and piston rods can be removed or installedthrough the suction valve opening. The valve springmust also be removed. It is recommended that a pistonand rod assembly be kept ready for replacement. Thisis a practical time saver.PISTON ROD The piston rods are manufactured ofhigh carbon steel and are plated to protect against cor-rosion. Rods also have a knurled section so the rod canbe held while tightening the piston nut. It is important

that the piston rod nut be tightened to the recom-mended torque as shown on page 32.The piston rod to piston fit is straight. The piston hubfits against the rod flange with an O ring gasket to pre-vent leakage. Removal of the piston is a simple opera-tion since it is not driven on a taper.

After removing the piston rod nut andthe rod to crosshead extension cou-pling, do not use a screwdriver or coldchisel to separate the piston rodflanges from either the extension rodflange or the piston hub, as burrs maybe formed which could cause mis-alignment on reassembly. Instead,rotate the eccentric slightly.If the parts do not separate, tap theflanges with a plastic, wood or raw-hide head hammer while rotating theeccentric.If the piston and piston rod are re-moved from the pump as a unit, theycan be separated by holding the rodand tapping the piston with the sametype of hammer.

PISTON WASHING SYSTEM The piston washingsystem is vital to satisfactory performance and life ofpistons and liners. The complete system must be keptin good operating condition. Washing fluid should bemaintained in good condition and should be replacedwhen contaminated to the point where free circulationis impaired. This is of utmost importance and should beimpressed upon all operators of the pump.The piston washing fluid may vary according to condi-tions and operators preference. Good results can beobtained using one part water with one part soluble oilwithin the closed system. Under severe freezing condi-tions a light undiluted oil gives good results.The more washing fluid circulated the better. However,it should be regulated by a valve in the discharge line ofthe centrifugal pump to prevent splashing and beingblown about by the wind. This could result in dangerousconditions around the pump when using any oil basedsolutions.

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FIGURE 6 ECCENTRIC SHAFT POSITIONING

Inches mm

Eccentric ID .0000/4.0015 101.6000/101.6381. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Shaft OD 4.0015/4.0025 101.6381/101.6635. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric to Main Shaft Fit .0000/.0025T .0000/.0635T. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLUID END CORROSIVE ATTACK Some aluminumbronze fluid cylinders and components (especiallyvalve decks and seats) experience corrosive attackfrom chemicals in the water being pumped. To avoiddamage to pump components, water containing corro-sive chemicals should be treated to neutralize corrosiveproperties before it is pumped.To determine if corrosive chemicals are present inpumped water, a sample should be chemically ana-lyzed and/or one or more sacrificial anodes should beplaced in the suction fluid stream. If the water analysisshows corrosive chemicals are present, or on frequentinspection the anode is observed to be eaten away, thefluid should be treated.

Anodes, mounted on threaded plugs, are available fromGardner Denver Machinery Inc. to replace one or moreof the drain plugs located in the bottom of aluminumbronze suction manifolds.

SERVICE INSTRUCTIONS POWER ENDECCENTRIC (FIGURE 5, page 17, and FIGURE 6,above) The drive shaft extension can be located oneither side of the pump by installing the eccentric in thedesired position. The lubricating pump is mounted onthe opposite side from the drive side on the pump.To remove eccentric, remove gear reducer hub, oilpump and bearing end plates from both sides. Mainbearings are tapered roller type and the cups remain in

the end plates as they are removed. The oil must be re-moved from the power end before eccentric removal.

Support shaft on a rope sling and remove eccentricshaft and bearing cones from sheave side of pump.Connecting rods will slip over the cams as the eccentricis removed.

Bearings are to be replaced if worn excessively or dam-aged. A damaged bearing will be noisy. Do not removeprotective grease in new bearings; it will not contami-nate the crankcase oil.

CROSSHEAD AND PINS Crossheads can be re-moved through the oil stop head openings. Remove in-spection plates from side of frame. Crossheads areequipped with straight fullfloating pins secured oneach end by spring retainers in grooves near the ends.The retaining rings can be reached through the cross-head inspection plate openings located on the sides ofthe frame. It will be necessary to remove one (1) out-side crosshead to gain access to the center pin.Remove the plunger clamp, stuffing box, plunger, andoil stop head. Next, slide the crossheads through oilstop head bores in frame and lift clear of the pump. Becareful to protect the lower slide from damage in theframe by placing a wooden block beneath the small endof the connecting rod. When reassembling, be sure theseals are in place on the oil stop heads.

Oversize crossheads are available from Gardner Den-ver Machinery Inc.

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CONNECTING RODS Eccentric must be removedbefore connecting rods can be removed. Rods havesolid bushings at the crosshead and the eccentric end.Each can be pressed out and replaced if necessary. Itis best to shrink new bushings by freezing before instal-ling in rod, instead of pressing in. Install crossheads,connecting rod and eccentric in reverse order of above.

MAIN BEARINGS Main bearings are the tapered roll-er type. The largest bearing is on the drive side of themain shaft and the smaller on the opposite end. Endclearance for both bearings is adjusted by the additionor removal of shims located on the end plate oppositethe drive side. End clearance should be .002/004(.051/.102 mm). Bearing cones are a shrink fit onto theeccentric shaft and the cups are a light fit in the endplates.

ECCENTRIC SHAFT ASSEMBLY PROCEDURE(FIGURE 6, page 18) Install key in the eccentric shaftand freeze the shaft before assembling into the eccen-tric bore. Use the dimensions shown in FIGURE 6,page 18, for correct positioning of the shaft.

EXTENSION RODS Each extension rod and integralcrosshead assembly can be removed from the pump byworking through handhole plates located on the sidesof frame and also through the oil stop head openings af-ter oil stop head assemblies have been removed. Becareful not to damage the highly polished surface onwhich oil seals travel.

Extension rods are plated and shouldbe protected when the pump is re-painted. Paint on the extension rodswill damage oil stop head seals whenthe pump is operated.

OIL STOP HEADS Oil stop head seals keep crank-case oil within frame and also help keep foreign materialfrom entering the crankcase.

Each oil stop head has two (2) lip ring seals. The seallips should face the crankshaft. When assemblingseals, care must be taken not to damage the sealing lip.Crosshead extension and seal rings should be coatedwith oil before seal assembly. The oil stop head mustbe assembled on frame, then one (1) seal at a time isinstalled over the crosshead extension rod into the oilstop head bore.

When installing oil stop head sealrings, care must be taken not to dam-age sealing lips. Damaged lips couldlead to excessive oil leakage and/orcrankcase contamination and dam-age.

Tighten oil stop head gland to prevent seal movementwhile pump is in operation. These oil stop head sealsare nonadjustable. When crankcase oil leakage occurspast seals, the seals should be replaced as additionaltightening of the gland will not prevent leakage.

It is essential that oil stop head seals be replaced at thefirst indication of leakage. Oil leakage will be indicatedby oil collecting on top of the liner washing water onmodels equipped with a reservoir. If rig water is usedfor washing and run to a waste area, it is difficult tocheck by above method. On models not equipped witha rod wash system check for oil collecting below stopheads in cradle.

If oil leakage is serious, it will appear in a lower oil levelin the crankcase. In this case oil must be added to thecrankcase as required until new oil stop seals can beinstalled.

When mud or other foreign material isfound in the crankcase, the oil mustbe changed before operating pump toavoid damage to moving parts.

Leakage of mud and water into crankcase will be indi-cated by a milky appearance of crankcase oil. Rubberbaffles are provided as standard equipment to reducethe amount of abrasive fluid entering power end andshould be installed on all three (3) extension rods. If ex-cessive, mud can be detected by reaching through theoil with the hand, or by draining out a small quantity ofoil. Mud will also be seen below the oil stop heads onthe inside of crankcase through crosshead inspectionplate openings.

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Failure to properly reinstall and main-tain baffles voids Warranty as they aredesigned to help prevent mud andother contaminants from enteringand damaging the crankcase.

When mud is found in the crankcase, the oil and filtershould be changed.

Drain and clean out the crankcase before putting in newoil. Replace the oil stop head seals before running thepump.

We recommend oil stop head seals be changed everysix (6) months of operation, even though leakage is notevident.

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CRANKCASE OIL REQUIREMENTS

CrankcaseAPIGL5 Ambient Operating Oil Minimum StartupOil Grade Temperature Temperature * Oil Temperature

75W90 20 F to 60 F 60 F to 140 F 20 F(29 C to 16 C) (16 C to 60 C) (7 C)

80W140 10 F to 100 F 90 F to 180 F 50 F(12 C to 38 C) (32 C to 82 C) (10 C)

80 10 F to 45 F 70 F to 125 F 30 F(23 C to 7 C) (21 C to 52 C) (1 C)

90 20 F to 80 F 100 F to 160 F 60 F(7 C to 27 C) (38 C to 71 C) (16 C)

140 50 F to 115 F 130 F to 195 F 80 F(10 C to 46 C) (54 C to 90 C) (27 C)

* An 80 F (27 C) crankcase oil temperature rise over ambient air temperature is typical for thepumps covered by this manual when operating at or near rated horsepower.

Oil viscosity must not exceed 7000 SSU at startup and must be between 1500 SSU and 200 SSUwhile operating, regardless of the oil temperature or grade used. A crankcase heater and/or an oil heatexchanger may be needed to meet these requirements.

Crankcase capacity is 12 gallons (45.4 liters).

Failure to follow these lubrication requirements will void the warranty.

Some operating conditions and/or oil brands produce excessive oil foaming, even when the specifiedGL5 oils containing antifoaming additives are used. Oil foaming can cause pump damage, as oilbubbles will not lubricate moving parts properly. If significant oil foaming occurs, contact Gardner Den-ver Machinery Marketing or Service for the current factory recommended defoamant to be added to thelubricating oil. When it is not possible to contact Gardner Denver people, a small amount of keroseneadded to the oil will usually reduce foaming. One half of a fluid ounce of kerosene added to each gallonof oil should be sufficient to control foaming. The use of larger amounts of kerosene per gallon of oil willreduce the oil viscosity, which could result in rapid pump wear and failure.

FIGURE 7 CRANKCASE OIL REQUIREMENTS

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PLUNGER PACKINGLUBRICATION RECOMMENDATION CHART

ROCK DRILL LUBRICANTSSource Type Pour Point Maximum

Amoco Amoco Rock Drill Oil Light 20Amoco Rock Drill Oil Medium 0

Arco Air Drill #147 0Arco Trueslide #150 15

Chevron Oil U.S.A. Vistac #68X 10Vistac #100X 5Vistac #150X 0

Conoco EP Rockdrill #49, #17, #78 5Gulf Oil (Chevron) Rockdrill #100 30

Rockdrill #32 35Exxon Arox EP #46 20

Arox #150 35Mobil Oil Co. Alamo #525 10

Alamo #527 25Alamo #529 10Alamo #532 0

Pacer Oil Rockdrill #150 10Rockdrill #600 0

Phillips Petroleum EP #500 (Summer) or EP #300 (Winter) 10Shell Oil Co. Torcula Oil #32 50

Torcula Oil #100 20Torcula Oil #150 15Torcula Oil #320 10

Sun Oil Co. Rockdrill 500 (Light) 5Rockdrill 1000 (Heavy) 5

Texaco Oil Co. Rockdrill Oil XL 40Rockdrill Oil XM 0Rockdrill Oil XH 20

Union Oil of Ca. Marok 150

STEAM CYLINDER OILSSource Type

Amoco Amoco Cylinder Oil 460Arco Modco Cylinder Oil 125, 175Conoco Inca Cylinder OilExxon Cylesstic TK460 or TK1000Gulf Oil (Chevron) Senate #375 Compound

Security #460 NonCompoundMobil Oil Co. Mobil Cylinder Oil 600WPacer Oil ComCyl OilPhillips Petroleum Hector Cylinder OilShell Oil Co. Valvata J460Sun Oil Co. Occident

Gear Oil 7X, Gear Oil 8CTexaco Oil Co. Pinnacle Cylinder Oil

31606 Page 23

GARDNER DENVER HORIZONTAL PUMPRECOMMENDED SYSTEM LAYOUT FOR PROPER PERFORMANCE

NOTES:1) Feed line and bypass line openings in tank must

be located below the top of baffle and on oppositeside of tank from outlet opening.

2) The baffle must be completely submerged at mini-mum liquid level in the tank. The baffle must beplaced between the feed line and tank outlet topump and should extend from one side of the tankto the other.

3) If a tank baffle cannot be installed, flow into thetank must be directed away from tank outlet topump so entrained gasses do not flow directly intotank outlet.

4) A short straight suction line is preferred from thetank to the pump. If this is not possible, use as fewbends as possible and use long radius elbows.The smallest portion of the line should be at least

as large as the pump suction opening. Flow veloc-ity should be 3 ft/sec or less.

5) Suction and discharge lines should each containa section of flexible hose to remove piping strainand vibration.

6) The suction stabilizer should be a bladder typewith an internal baffle between the inlet and outletconnections.

7) NPSH provided by suction system must be ade-quate to satisfy pump requirements. Refer toNPSHR curve or consult GardnerDenver Mar-keting.

8) A bladder type discharge pulsation dampener isrecommended.

9) Discharge line flow velocity should be 10 ft/sec orless.

31606 Page 24

NET POSITIVE SUCTION HEAD REQUIRED (NPSHR)*AT FLUID CYLINDER SUCTION CONNECTION WITH SUCTION STABILIZER

AND DISCHARGE PULSATION DAMPENER INSTALLED,FOR TEE LOW PRESSURE AND MEDIUM PRESSURE FLUID CYLINDERS

Pump Bulletins list maximum and minimum plunger sizes. Interpolate between NPSH curves for each plunger size.

* NPSHR is defined at a 3% flow drop below maximum capacity. Added suction head above that shown by the curves must be provided for the higher vapor pressure of warmerwater (curves are based on 60 F water) and/or other fluids and for acceleration head and friction losses insystems having long and/or restricted suction lines..

31606 Page 25