Price $5.

00
3-1-605
I st Edi ti on
PAH
TRIPLEX PUMP
31-605
n
~ ~ GARDNER-DENVER
COOPER
INDUSTRIES INDUSTRIAL MACHINERY DIVISION
Gardner-Denver (the Company) warrants i ts products onl y
as fol l ows:
GENERAL PROVI S1ONS AND LI MI TATI ONS
The Company warrants to each ori gi nal retai l purchaser
(Purchaser) of i ts new products fr om the Company or
i ts authori zed di stri butor that such products are, at the
ti me of del i very to the Purchaser, made wi th good materi al
and workmanshi p, provi ded that no warranty i s made wi th
respect to:
1.
2,
3.
4.
5.
Any pr oduct whi ch has been repai red or al tered i n
such a way, i n the Companys judgment, as to affect
the pr oduct adversel y.
Any pr oduct whi ch has, i n the Companys judgment,
been subject to negl i gence, acci dent, i mproper storage,
or i mproper i nstal l ati on or appl i cati on.
Any pr oduct whi ch has not been operated or mai n-
tai ned i n accordance wi th normal practi ce and wi th
the recommendati ons of the Company.
Components or accessori es manufactured, warranted
and servi ced by others.
any recondi ti oned or pr i or owned product.
Cl ai ms for i tems descri bed i n (4) above shoul d be submi tted
di rectl y to the manufacturer.
The Companys obl i gati on under thi s warranty i s l i mi ted to
repai ri ng or, at i ts opti on, repl aci ng, duri ng normal busi ness
hours any part whi ch i n i ts judgment proved not to be as
warranted wi thi n the appl i cabl e Warranty Peri od. Duri ng the
fi rst 90 days after start-up, not to exceed 120 days after
del i very, a new part or a repai red part al ong wi th the l abor
for i nstal l ati on ofsuchnew orrepai red part wi l l be provi ded.
Such parts and l abor wi l l be provi ded wi thout charge to the
user duri ng normal worki ng hours at the Companys or
authori zed di stri butors servi ce faci l i ty. Al l costs of trans-
portati on of pr oduct or parts cl ai med not to be as warranted
and of repai red or repl acement parts to or fr om such servi ce
faci l i ty shal l be borne by the Purchaser. The Company may
requi re the r etur n of any pr oduct or part cl ai med not to be
as warranted to one of i ts faci l i ti es as desi gnated by Company,
transportati on prepai d by Purchaser, to establ i sh a cl ai m
under thi s warranty.
Repl acement parts provi ded under the terms of thi s warranty
are warranted for the remai nder of the Warranty Peri od of
the pr oduct upon whi ch i nstal l ed to the same extent as i f
such parts were ori gi nal components thereof,
GARDneR-DENVER
TRI PLEX AND QUI NTUPLE PUMPS
WARRANty PERI OD
Except for the products or components l i sted bel ow, the
Warranty Peri od for al l products i s 1,250 hours of operati on
or three months after start-up, not to exceed 120 days after
del i very to Purchaser, whi chever occur s fi rst. The excepti ons
are as fol l ows:
Power end i s warranted for 12 months fr om date of
start-up or 18 months fr om date of del i very to the
Purchaser, whi chever occur s fi rst.
Fl ui d end i s condi ti onal l y warranted on pro-rata basi s for
three years fr om date of del i very to the Purchaser.
Expendabl e fl ui d end parts, i ncl udi ng val ves, val ve parts,
l i ners and pi stons, are not covered by thi s warranty due
to vari abl e abrasi ve nature of materi al pumped.
DI SCLAI MER
THE COMPANY MAKES NO OTHER WARRANTY OF
ANY KI ND WHATSOEVER EXPRESSED OR I MPLI ED
AND ALL WARRANTI ES OF MERCHANTABI LI TY AND
FI TNESS FOR A PARTI CULAR PURPOSE ARE HEREBY
DI SCLAI MED BY THE COMPANY. THE COMPANY
SHALL I N NO CASE BE SUBJECT TO ANY OTHER
OBLI GATI ONS OR LI ABI LI TI ES WHATSOEVER WI TH
RESPECT TO PRODUCTS OR SERVI CES MANUFAC-
TURED OR FURNI SHED BY I T OR ANY ACTS OR
OMI SSI ONS RELATI NG THERETO. THE REMEDY PRO-
VI DED UNDER THI S WARRANTY SHALL BE THE SOLE,
EXCLUSI VE AND ONLY REMEDY AVAI LABLE TO PUR-
CHASER. UNDER NO CI RCUMSTANCES SHALL THE
COMPANY BE LI ABLE FOR ANY SPECI AL, I NDI RECT,
I NCI DENTAL OR CONSEQUENTI AL DAMAGES, EXPEN-
SES, LOSSES OR DELAYS HOWSOEVER CAUSED.
NO statement, representation) agreement or understandi ng,
oral or wri tten, made by any agent, di stri butor, representati ve,
or empl oyee of the Company whi ch i s not contai ned i n thi s
Warranty wi l l be bi ndi ng upon the Company unl ess made i n
wri ti ng and executed by an offi cer of the Company.
Thi s warranty shal l not be effecti ve as to any cl ai m whi ch
i s not presented wi thi n 30 days after the date upon whi ch
the pr oduct i s cl ai med not to have been as warranted. Any
a. ti on for breach of thi s warranty must be commenced
wi thi n one year after the date upon whi ch ch the cause of
acti on occur r ed.
Any adjustment made pursuant to thi s warranty shal l not be
construed as an admi ssi on by the Company that any pr oduct
was not as warranted.
3-1-605 Page 1
TABLE OF CONTENTS
WARranTY . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . ...2
I NSTALLATI ON . . . . . . . . . . . . . . . . . . . . . . . . ...3
Locati on . . . . . . . . . . . . . . . . . . . . . . . . . . ...3
Sucti on Pi pi ng . . . . . . . . . . . . . . . . . . . . . . ...3
Rel i ef Val ve . . . . . . . . . . . . . . . . . . . . . . ...3
Lubri cati on . . . . . . . . . . . . . . . . . . . . . . . . ...3
Starti ng aNew Pump . . . . . . . . . . . . . . . . . ...3
Operati on . . . . . . . ...+
SECTI ONAL VI EW OF PUMP
SERVI CE I NSTRUCTI ONS
Cyl i nder . . . . . . . . . . . .
. . . . . . . . ...+ . . . . . 4
. . . . . . . . . . . . . . . . . 5
FLUI D END . . . . ...6
. . . . . . . . . . . . . . . . . 6
val ve s. . . . . . . . . . . . . . . . . . . . . . . . . . ...6
Pl unger . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Pl unger Stuffi ng Box Packi ng.. . . . . . . . . . ...7
Lubri cator . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Pi ston Li ners and Li ner Cl amps. . . . . . . . . . . . . 7
Pi stons . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Pi ston Rod . . . . . . . . . . . . . . . . . . . . . . . . ...7
Pi ston Washi ng System . . . . . . . . . . . . . . . . ...7
SERVI CE I NSTRUCTI ONS POWER END . . . . . . 9
JackShaft . . . . . . . . . . . . . . . . . . . . . . . . . ...9
Connecti ng Rods . . . . . . . . . . . . . . . . . . . . . . 10
Eccentri c and Beari ng Assembl y . . . . . . . . . . . 10
Mai n Gears, . . . . . . . . . . . . . . . . . . . . . . . . . 10
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crossheads and pi ns . . . . . . . . . . . . . . . . . . . . 11
Oi l Stop Heads . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Runni ng Cl earances. . . . . . . . . . 12
Manufacturi ng Fi ts . . . . . . . . . . . . . . . . . . . . . 12
Recommended Torques . . . . . . . . . . . . . . . . . . 12
3-1-605 Page 2
OPERATI NG AND MAI NTENANCE I NSTRUCTI ONS
FOR PAH TRI PLEX PUMP
I NSTALLATI ON
1. LOCATI ON The pump shoul d be i nstal l ed as cl ose
to the fl ui d suppl y and as l ow as possi bl e. Whenever pos-
si bl e, ampl e space shoul d be provi ded around the pump
to faci l i tate i nspecti on and adjustment, wi th parti cul ar atten-
ti on bei ng gi ven to the space requi red for removal and
i nstal l ati on of jackshaft, eccentri c, packi ng etc.
The dri ve must be accuratel y al i gned pump pr oper l y l evel ed
and securel y fastened to foundati on or base.
Pump must have a posi ti ve sucti on head, 10 foot (3048 cm)
mi ni mum. Maxi mum al l owabl e temperature of fl ui d handl ed
i s 200 F. (93 C.).
2. SUCTI ON PI PI NG Sucti on pi pe (or hose i f used)
shoul d be the ful l si ze of the sucti on openi ng. I f for any
reason the sucti on l i ne i s of gr eater l ength than usual , the
next l arger si ze shoul d be used. A l ong hori zontal sucti on
l i ne shoul d sl ope up toward the ump at uni form grade
so that ai r pockets are el i mi nated. Sucti on l i ne must be
absol utel y ti ght as any si r l eaki ng i nto the l i ne wi l l r educe
the capaci ty of the pump. I f i t i s necessary to have bends
i n the sucti on l i ne, they shoul d have l ong radi us sweeps.
al l pi pi ng must be supported i ndependentl y of the pump
to i nsure that no strai n i s i mposed on the pump by mi s-
al i gnment or i mproperl y fi tted pi pe.
3. RELI EF VALVE The pump must be pr otected
shoul d be i nstal l ed near the pump,
safety val ve and the pump cyl i nder. The rel i ef val ve shoul d
be set to oper ate at approxi matel y 1-1/4 ti mes the di scharge
pressure.
4. LUBRI CATI ON The power end i s l ubri cated by
oi l wi thi n the crankcase. Gear oi l API Ser vi ce Cl assi fi cati on
GL-4 SAE 90 i s recommended. Essenti al addi ti ves for
oi l are rust, foam and oxi dati on i nhi bi tors.
i n freezi ng weather, warm oi l befor e starti ng pump. I t
i s al so recommended that a col d pump be brought up to
speed gradual l y, i f possi bl e.
Crankcase capaci ty i s 30 U.S. gal l ons (113.6 l i ter).
Oi l must be added as requi red to mai ntai n the l evel to
top of the oi l l evel gauge on the si de of the frame.
Ti me between oi l changes depends on l ocal or operati ng
condi ti ons. ordi nari l y, i f the crankcase i s kept cl osed,
i t shoul d not be necessary to change oi l mor e often than
once i n 1000 worki ng hours. The pressure auge must
h be watched and i f i t shows l ack of pressure, t e oi l l evel
shoul d be checked. Oi l shoul d be changed i f found to be
di rt . The scr een on the sucti on of the ci rcul ati ng pump
h mi g t be stopped up so the pump cannot get suffi ci ent
oi l to mai ntai n pressure. Thi s scr een shoul d be exami ned
at rather frequent
i nterval s and thoroughl y cl eaned. I t
can be r emoved wi thout draining the oi l from the crank-
case.
3-1-605
When overhaul i ng pump , check al l oi l connecti ons and
h; cl ean al l l i nes thor oug y. The oi l rel i ef val ve shoul d al so
be i nspected.
I f pump i s to be stor ed or shut down for an extended peri od
and i f oi l regul arl y used does not contai n an addi ti ve for
rust preventi on drai n the oi l from the crankcase and add
an oi l base rust preventati ve, then turn pump over a few
ti mes to coat worki ng parts. Thi s wi l l pr otect the power
end parts agai nst damage by rust. Befor e pum i s agai n
pl aced i n operati on, drai n crankcase and fi l l wi th new oi l .
Oi l pump i s the gear-dri ven r otar y type pump whi ch pr o
ti des fal tered oi l under pressure to connecti ng r od l i ners
and crosshead pi n bushi ngs. Crossheads and gui des are
l ubri cated by fl ood from gear. The pump i s reversi bl e and
wi l l del i ver oi l regardl ess of the di recti on of rotati on. Al l
the oi l pumped i s fi l tered befor e i t goes to the beari ngs.
I t i s recommended that an i ndependentl y dri ven oi l pump,
dri ven at a constant speed, be used on wel l servi ci ng ti ts.
Oil Filter A repl aceabl e el ement oi l fi l ter i s l ocated i nsi de
the pump crankcase. Fi l ter mounti ng fl ange i s on the out-
si de, maki ng i t possi bl e to repl ace the el ement by removi n
end pl ate. onl y the oi l wi thi n the fi l ter case wi l l be spi l l ed
when el ement i s wi thdrawn.
Fi l ter el ement shoul d be repl aced each ti me crankcase oi l
i s changed or ever y 1000 hours.
Fi l ter el ement i s pr otected from excessi ve i nternal oi l pres-
sure by a rel i ef val ve between i t and the oi l pump. Rel i ef
val ve setti ng i s 110 PSI G (7.73 kg/cm2 ),
Oi l fl ows through the oi l ti ter befor e goi ng through the
heat exchanger.
Heat Exchanger (Opti onal Equi pment) A bronze heat
exchanger can be provi ded to keep crankcase oi l tempera-
tur e at 160 F. (710 C ) by means of an automati c water
control val ve.
5. STARTI NG A NEW PUMP Pumps are shi ped
from the factory wi thout oi l i n the crankcase. The ood
shoul d be r emoved and the power end exami ned and cl eaned
i f necessary. The pump may have been i n storage or i n the
yard for some ti me and as a consequence, di rt or rust from
condensati on may have formed i n the crankcase. Al SO,
parts may have been robbed from the pump duri ng storage
and not repl aced. Drai n al l water accumul ated i n the bottom
of the crankcase, check nuts and screws and ti ghten i f
necessary. Fi l l crankcase wi th oi l of pr oper grade and to
pr oper l evel .
WELL SERVI CI NG PUMPS MUST BE DRI VEN ONLY
I N THE DI RECTI ON I NDI CATED. Other PAH pumps
can be dri ven i n ei ther di recti on but the i ndi cated di recti on
i s recommended because the crosshead l oad wi l l be carri ed
on the bottom gui de, resul ti ng i n mor e qui et operati on and
better l ubri cati on.
The direction of rotation of the jackshaft i s i ndi cated by
Page 3
an ar r ow on the frame. To pr event excessi ve wear on the
fl ui d pi stons or pl ungers and packi ng when starti ng r emove
the di scharge val ve cover pl ates and di scharge val ves and
pri me the pump. PRI MI NG I S I MPORTANT! I T LUBRI -
CATES PLUNGERS OR PI STONS AND LI NERS. Pump
shoul d be started sl owl y and shoul d be oper ated for several
hours wi th practi cal l y no di scharge ressure. Check oi l l evel
as i t may be necessary to add a sm& amount of oi l to com-
pensate for that adheri ng to the wal l s of the crankcase and
movi n parts, The pump may then gradual l y be brought up
ul l to f speed and ful l worki ng pressure. Watch for undue
heati ng or abnormal noi se i n the worki ng parts. Check al l
joi nts i n the sucti on l i ne to be sure ther e are no ai r l eaks.
Befor e starti ng a pump whi ch has been i dl e for a l ong peri od
of ti me, drai n any water due to condensati on from crankcase
by removi ng the drai n pl ug and repl ace when cl ean oi l
begi ns to fl ow from the drai n. Add oi l to pr oper l evel . I t
i s recommended that fl ui d end of the pump be pri med to
pr event excessi ve wear on the pl ungers or pi stons and l i ners
when starti ng. PRI MI NG I S I MPORTANT! I T LUBRI -
CATES PLUNGERS OR PI STONS AND LI NERS.
Pump shoul d al ways be started sl owl y, and wi th l i ttl e pres-
sure, after i t has been i dl e or wher e i t i s on i ntermi ttent
servi ce such as wel l servi ci ng. Thi s gi ves the oi l a chance
to warm up and fl ow through al l oi l l i nes and beari ngs.
Thi s warm-up i s especi al l y i mportant duri ng col d weather,
6. OPERATI ON The PAH pump shoul d not be op
er ated at speeds or pressures exceedi ng the val ues shown
on the name pl ate.
3-1-605 Page 4
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SERVICE INSTRUCTIONS
FLUJD
7. CYLi nDER Two di fferent styl e cyl i nders are pr o
ti ded for the PAH pumps to sui t the servi ce. Both styl e
cyl i nders are the thr ee-pi ece bl ock type. Materi al i s heat
tr eated for ed al l oy steel . The fl ui d end i s provi ded wi th
removabl e bol ted-on sucti on and di scharge mani fol ds.
Cyl i nder i s secured to the frame by hi gh tensi l e strength
connecti ng studs. I t i s i mportant that nuts on these studs
be checked occasi onal l y for ti ghtness. A l oose nut wi l l
cause a stud to break under pul sati ng l oad. See pr oper
ti ghteni ng torque on page 12.
The connecti ng studs extend through the stuffi ng box or
l i ner cl amp fl anges to cl amp the stuffi ng boxes or l i ners
ti ghtl y agai nst the face of the cyl i nder.
B702
FI GURE 2. BLOCK-TYPE FLUI D CYLI NDER
FOR WATER FLOOD SERVI CE
8. VALVES I n or der to keep the pump i n i ts best
operati n condi ti on, i t i s necessary to exami ne the sucti on
and di scharge val ves occasi onal l y to see that excessi ve wear
or cutti ng by the sl ush or mud has not i mpai red thei r effi -
ci ency. any wor n or damaged parts shoul d be repl aced.
Thi s i s especi al l y true wi th r egar d to the i nserts. Standard
i nserts are made of urethane and are the part of the val ve
whi ch shoul d be changed most frequentl y. They are much
cheaper than the val ves and seats, and i f i nserts are r enewed
as soon as they begi n to fai l , the mor e expensi ve steel parts
3-1-605
END
wi l l l ast much l onger. Routi ne i nspecti on of val ves ever y
two or thr ee days i s recommended on dri l l i ng and wel l
servi ci ng uni ts.
To r emove Water Fl ood Ser vi ce Val ves, r emove the di s-
charge val ve cover stud nuts and val ve cover s. Remove
di schar e val ve cage,
h
spri ng and val ve and pul l the seat
from t e taper bor e wi th a pul l er. Repeat thi s same pr o
cedur e for the sucti on val ves. The di scharge val ves are l arger
than the sucti on val ves to permi t i nstal l i ng and r emov-
i ng sucti on val ves through the di scharge val ve deck i n the
cyl i nder.
To r emove Dri l l i ng and Wel l Ser vi ce Val ves r emove sucti on
and di scharge cover l ocks and val ve cover s and the sucti on
val ve gui de retai ner and gui de and l i ft val ve and spri ng
from seat. The seat may be pal l ed from the tapered bor e
wi th a pul l er.
NOTE: If a seat puller powered by a hydraulic jack is
used, be certain to chain or tie the jack down
as it will jump violently when valve seat lets go.
If it becomes necessary to resort to the use of
heat or a cutting torch to remove a valve seat,
the services of a man experienced in this opera-
tion is necessary.
Befor e putti ng new seats i n the pump, the tapered bor e
i n the val ve seat deck must be thoroughl y cl eaned of mud
or sl ush wi th a wi r e brush. Wi re brush shoul d be used around
the bor e rather than up and down. Wi pe the bor e cl ean and
do not use oi l or grease. The bor e must be cl ean and dr y or
seat may not seat properl y.
Pl ace the new seat i n the bore. Use an ol d val ve bumper or
a bl ock of hard wood and dri ve wi th a sl edge to a snug
i ni ti al fi t. The pressure l oad on the val ve i n operati on wi l l
dri ve the seat home. NOTE: Never reuse an old seat once
it has been removed forn a cylinder, as it may not jit solidly
in the valve deck.
Do not put a used val ve assembl y on a new seat unl ess i t
i s i n practi cal l y a new condi ti on. Be sure to repl ace a doubt-
ful i nsert to pr otect seat and bumper.
Repl ace the upper val ve gui de i f wor n (dri l l i ng and wel l
servi ce uni ts onl y). Repl ace the val ve spri ng i f i t i s worn,
cor r oded, di storted or bel ow normal tensi on. Val ves are
provi ded wi th stai nl ess steel s ri ngs for maxi mum oper -
sti ng l i fe. A br oken spri ng wi l l cause rapi d wear of val ve
gui des (wher e used) and s oul d be repl aced I t wi l l al so
cause wear on sucti on val ve gui de mounti ng l ugs i nsi de the
cyl i nder.
I t requi res exper i ence and judgement to determi ne i f val ve
parts shoul d be repl aced or not. Val ves are cheaper than
down ti me.
When i nstal l i ng val ves put the gasket careful l y i n pl ace i n
the val ve chamber and i nstal l cover pl ate. Be certai n gasket
i s not twi sted or extruded, On drilling and well service units
ti ghten val ve cover l ock securel y by usi ng a bar and hammer.
On water fl ood uni ts ti ghten each val ve cover stud nut to
Page 6
the pr oper torque to prel oad studs to 400 foot-pounds
(55 kg-m) (542 Nom). Ti ghten cage val ve cage to seat 4
to 6 turns to a torque of 120 foot-pounds (16.6 kg-m)
(163 N-m) for sucti on and 140 foot-pounds (19.4 kg-m)
(190 Nom) for di scharge.
The l i fe of the val ves wi l l be l engthened i f the mud tanks
are kept cl ean. Forei gn objects can be caught under the
val ves, thereby hol di ng them open and causi ng rapi d cutti ng
of the seats and val ves.
9. PLUNGER Water Fl ood and Wel l Servi ci ng Units
To r emove a pl un er , r emove coupl i ng bol t and coupl i ng
whi ch hol ds the pl unger to the push rod. Turn the pump
over unti l the pl unger i s i n the stuffi ng box as far as i t
wi l l go. Conti nue to turn pump ti l l push r od i s backed
away from pl unger as far as i t wi l l go. Remove stuffi ng
box wi th pl unger and packi ng i n the box as a compl ete
uni t. Pul l pl unger out of packi ng. The packi ng can be i n-
stal l ed i n the box over the pl unger, but the pr efer r ed
method i s to i nstal l the packi ng, then grease the pl unger
and push through the packi ng. Ti ghten the gl and as much
as possi bl e. Keep gl and ti ght to pr event movement of
packi ng.
To repl ace the assembl y i n pump, r ever se above pr ocedur e.
Pumps are equi pped wi th pl ungers made of materi al s as
requi red for the servi ce. Hardened steel and cohnonoy
pl ungers are avai l abl e for the dri l l i ng and wel l servi ci ng
uni ts. Col monoy pl ungers onl y are avai l abl e for the water
fl ood pumps.
Ti ghten frame to cyl i nder and stuffi ng box studs to pr oper
torque of 500 foot-pounds (69 k-m) (678 Nom).
10. PLUNGER STUFFI NG BOX PACKI NG Pl unger
stuffi ng boxes are packed wi th non-adjustabl e packi n
The stuffi ng box gl and must engage at l east thr ee thread
to hol d the pressure of the pump.
Al ways i nstal l a compl ete set when renewi ng packi ng. Cl ean
stuffi ng box thoroughl y befor e i nstal l i ng new packi ng.
I nstal l junk ri ng i n bottom of stuffi ng box. Oi l each ri ng
thoroughl y and i nstal l one at a ti me, begi nni ng wi th the
h bottom adaptor ri ng. Make sure the l i ps of t e packi ng
face the pressure. Ti ghten gl and bol t as much as possi bl e.
Be sure that the gl ands do not back off whi l e the pump
i s operati ng. Lock i n pl ace wi th l ock pi ns.
Keep packi ng l ubri cated at regul ar i nterval s by addi ng
mul ti purpose grease NLGI Grade No. 2 at the grease fi t-
ti ngs l ocated on the top of the stuffi ng boxes.
11. LUBRI CATOR A for ce-feed l ubri cator i s avai l abl e
as opti onal equi pment to suppl y oi l to the thr ee stuffi ng
boxes. Lubri cator i s mounted on a bracket over the frame
and i s dri ven by l i nkage connected to a crosshead extensi on.
Oi l i s del i vered to the tapped openi ng i n each stuffi ng box
through copper tubi ng. Lubri cator i s equi pped wi th a check
val ve at each outl et connecti on. Use a good grade of engi ne
oi l , API Ser vi ce Cl assi fi cati on SC SAE 30.
Provi de fl ow of 6 to 8 dr o s per mi nute to each stuffi ng
box by rotati ng the contr o to i ncrease or decrease, then
ti ghten l ocknut:
12. PI STON LI NERS
l i ners are rei nstal l ed or
AND LINER CLAMPS When
repl aced i t i s advi sabl e to check
3-1-605
cyl i nder to frame stud nuts and ti ghten i f necessary. Refer
to page 12 for pr oper ti ghteni ng torques.
Nuts hol di ng l i ner cl am si n pl ace shoul d not be overti ghten-
ed as di storti on of the l i ner cl amp and l i ner bor e may resul t.
Recommended ti ghteni ng torque i s shown i n tabl e on page
12.
Change si ze of pi stons and l i ners as vol ume and/or pressure
requi rements change.
Li ners are repl aced by removi ng the l i ner cl amps. They
shoul d be cl eaned and oi l ed after removal to pr otect agai nst
rusti ng duri ng storage, so they can be used agai n i f they
are i n usabl e condi ti on,
Pump l i ners are to be cl ean both i nsi de and out when i n-
stal l ed. Al so cl ean the l i ner cl amp bor e and l i ghtl y oi l al l
surfacea.
Use new gaskets when i nstal l i ng l i ners and be sure to cl ean al l
surfaces agai nst whi ch the gaskets fi t. Li ners or fl ui d cyl i n-
ders may be cut by l eaki ng gaskets. i f pi stons are pr oper l y
mai ntai ned ther e wi l l be l i t e or no cutti ng of the l i ners.
13. PI STONS Si ngl e-acti ng pi stons are made up of
h speci al body fi tted wi t a speci al pi ston i nsert devel oped
for these si ngl e-acti ng pumps.
Pi ston, wi th pi ston rods, can be r emoved or i nstal l ed through
sucti on val ve openi ng after upper val ve gui de i s r emoved by
turni ng i t 900. Val ve spri ng must al so be r emoved.
I t i s recommended that a pi ston and r od assembl y be kept
ready for repl acement. Thi s i s a practi cal ti me saver.
14. PISTON ROD Pi ston rods are manufactured of
hi gh carbon steel . They are el ectrol yti cal l y pl ated to pr otect
agai nst corrosi on. They are provi ded wi th a knurl ed secti on
so r od can be hel d whi l e ti ghteni ng pi ston nut. I t i s i mpor-
tant that pi ston r od nut be ti ghtened to recommended
torque shown on page 12.
Pi ston r od to pi ston fi t i s strai ght. pi ston fi ts agai nst fl ange
on pi ston r od wi th an O ri ng gasket to pr event l eakage.
Removal of pi ston i s a si mpl e operati on si nce i t i s not dri ven
on a taper. Keep pi ston r od to push r od cl amps ti ght at al l
ti mes to pr event damage to thei r fl anges and pi l ots. DO
NOT use a scr ewdr i ver or col d chi sel to separate the fl anges.
Turn the pump sl i ghtl y or use a pul l er scr ewed onto pi ston
r od threads wher e they extend beyond pi ston nut.
15. PISTON WASHING SYSTEM The pi ston washi ng
system i s vi tal to the sati sfactory performance and l i fe ,f
pi stons and l i ners. The compl ete system must be kept i n
good operati ng condi ti on. Washi ng fl ui d shoul d be mai n-
tai ned i n good condi ti on and shoul d be repl aced when
contami nated to the poi nt wher e fr ee ci rcul ati on i s i mpai red.
Thi s i s of utmost i mportance and shoul d be i mpressed upon
al l oper ator s of the pump.
Water suppl y l i nes shoul d be permanentl y attached to the
provi ded i n the ci rcul ati ng pump sucti on l i nes
between the ci rcul ati ng pump and the tank. Water i s then
qui ckl y avai l abl e as a washi ng fl ui d or to fl ush out the l i nes
by operati ng the pr oper val ves i n the pi pi ng system.
The pi ston washi ng fl ui d may be vari ed accordi ng to condi -
ti ons and oper ator s pr efer ence. Water makes a sui tabl e
washi ng fl ui d under most condi ti ons. Good resul ts can be
Page 7
obtai ned usi ng water wi th one-hal f gal l on of sol ubl e oi l per be regul ated by a val ve i n the di scharge l i ne of the centri -
tank of water wi thi n the cl osed system. A l i ght oi l gi ves fugal ci rcul ati ng pump to pr event spl ashi ng and bei ng
good resul ts under some condi ti ons, and can be used under bl own about by the wi nd. Besi des maki ng thi ngs messy
sever e freezi ng condi ti ons. and wasti ng washi ng fl ui d thi s coul d resul t i n dan erous
h condi ti ons around the pump when usi ng any of t e oi l
The mor e fl ui d ci rcul ated, the better; however , i t shoul d based sol uti ons.
3-1-605 Page 8
SERVICE INSTRUCTIONS
POWER
Remove hood and crosshead i nspecti on pl ates for access
to worki ng parts. Befor e worki ng i n i nsi de of crankcase,
i t i s necessary to drai n the oi l . oi l pump mounti ng and
pi pi ng connecti ons are bel ow the oi l l evel .
mark al l parts duri ng di smantl i ng so they can be r etur ned
to thei r ori gi nal posi ti on duri ng assembl y.
16. JACKSHAFT I t i s advi sabl e to r emove eccentr i c
and gear assembl y befor e attempti ng to r emove the jack-
shaft. Jackshaft beari ngs wi U not cl ear the gears.
FI GURE 3.
Remove al l sheaves or other dri ve members from the jack-
shaft. Support each end of shaft duri ng removal .
Remove beari ng retai ner from i nner end of beari ng housi ng.
Remove beari ng end pl ate from each si de of the pump. Re-
move beari ng housi ng from one si de and pul l jackshaft and
beari ng assembl y through thi s openi ng. Opposi te beari ng
housi ng need not be r emoved from the frame.
3
A K HAFT
,GASKET 8 SHIM
END
Jackshaft beari ngs are of the doubl e spheri cal type wi th end
thrust i n both di recti ons taken on the ri ght hand beari ng.
Both beari ngs are i denti cal .
The safest way to r emove the beari ngs from the jackshaft
i s by the careful use of heat. Do not over heat to the poi nt
wher e beari ng i s di scol ored.
When repl aci ng ackshaft beari ngs i t i s necessary to make
a spl i t di sc to cl amp on shaft and agai nst i nner face of the
outer beari ng r ace to hol d r ace square wi th axi s of beati ng.
See detai l i n Fi gure 3.
The jackshaft beari ngs shoul d be repl aced i f any of the
rol l ers or races show damage or i f they are excessi vel y
worn. A noi sy beari ng i ndi cates beari ng darnage, requi ri ng
repl acement. Check cl earances by i nserti ng feel er gauge
between the rol l er and i nner r ace wi th beari ng assembl ed
on the shaft and i n the housi ng. Thi s check can be made
wi th the beari ng assembl ed out of the pump. See r ecom-
mended runni ng cl earances on page 12.
To mount new beari ngs, i nstal l spl i t di sc (Fi gure 3 on
shaft as shown i n Fi r e 4. Heat beari ng i n oi l to about
300 F. (149 C.) an sl i p i t on the shaft agai nst the bear-
i ng shoul der and spl i t di sc. The shaft can then be rei nstal l ed
i n the frame, fol l owed by the eccentr i c assembl y.
To reassembl e the jackshaft i n the pump, i t i s necessary to
r ever se the pr ocedur e of removal . The teeth of the i ni on
can mesh i n onl y one di recti on, ther efor e, the jackshaft
i s not i nterchangeabl e end for end i n the pump unl ess gear
and eccentr i c assembl y i s al so r ever sed. Reversal of the
compl ete gear set i s permi ssi bl e after gear or pi ni on teeth
become badl y worn. When gear set i s r ever sed i t i s necessary
to i nstal l a new oi l pump dri ve pi ni on to match the opposi te
spi ral mai n gear.
Recommended di recti on of rotati on of the pump provi des
/e>/_- SPLIT DISC - USE
DURING INSTALLATION
L
1-------1 \
R-
OF BEARING AND
m-? HOUSING
d ERRETAINER
u
FI GURE 4. JACKSHAFT BEARI NG
D74236
I NSTALLATI ON
3-1-605 Page 9
that outer ends of gear and pi ni on teeth l ead. Thi s means
that when vi ewi ng from the hood openi ng the outer ends
of the gear teeth poi nt upward toward the jackshaft and
the outer ends of the pi ni on teeth poi nt toward the ear.
f Gears may be r ever sed but the di recti on of rotati on o the
WELL SERVI CI NG PUMP MUST NOT BE REVERSED.
I nner ends of teeth wi l l l ead after gear set has been r ever sed.
After jackshaft i s i n pl ace wi th the pi ni on i n mesh wi th
the gear, i nstal l the beari ng housi ngs. The housi ng i s to be
started on the beari ng and i n the bor e of the frame and
l i ghtl y dri ven i n. Be careful to keep di rt from beari ngs
duri n assembl y. Be sure the gasket i s on the housi ng. Long
threaded studs may be used to pul l the housi ng i nto the
frame bore. I t i s wel l to wor k both ends at the same ti me
after they have been wel l started over the beari ng outer
race. Thi s wi l l mi ni mi ze end thrust on the gear teeth. per -
manentl y bol t ackshaft beari ng housi ngs and r emove the
d spl i t di scs use for posi ti oni n beari ngs duri ng assembl y.
When di scs are r emoved i nst the beari ng i nner retai ner,
wi th cap screws and l ocki ng wi re, on the ri ght hand si de
of pump onl y.
The outer grease seal s are to be pl aced i n the beari ng end
pl ates after they are bol ted to the beari ng housi ngs and
frame. Coat i nsi de of the oi l seal s l i beral l y wi th beari ng
grease. Each outer seal i s to be i nstal l ed wi th gar ter spri ng
to i nsi de, toward beari ng. Seal bears on a repl aceabl e wear
sl eeve shrunk onto shaft to pr event wear under the seal ,
17. CONNECTING RODS The connecti ng rods are
spl i t and bol ted together on shi ms used pri nci pal l y to absorb
normal factory manufacturi ng tol erances. I f the eccentr i c
assembl y i s to be r emoved from the frame, the connecti ng
rods need not be unbol ted. i n thi s case the crosshead pi ns
must be r emoved. Eccentri c and r od assembl y wi l l l i ft out
of the frame fr eel y i f l eft hand eccentr i c i s posi ti oned
di rectl y above the shaft.
Whether or not the connecti ng rods need be r emoved de-
pends upon the nature of wor k bei ng done on the pump.
Connecti ng r od caps can be r emoved i n case i t i s desi red
to r emove eccentr i c assembl y onl y i n or der to repl ace mai n
beari ngs.
The connecti ng rods are provi ded wi th hi gh l ead bronze
l i ners whi ch bear agai nst the eccentri c. The l i ners are pr e-
ci si on made i n i denti cal hal ves and are secured by cl amps
hel d to the connecti ng r od and cap by cap screws. They
can be repl aced by removi ng connecti n r od caps, but
wi thout removi ng connecti ng r od body from the pump.
The shi ms between connecti ng rods and thei r caps can
be used to adjust l i ner to eccentr i c runni ng cl earance to
a l i mi ted degr ee. i n no i nstance shoul d an adjustment
18. ECCENTRI C AND BEARI NG ASSEMBLY
IMpoRTANT: Be sure to remove oil pump drive pinon
when removing or replacing eccentric and gear assembly
to avoid bending oil pump shaft when gear is moved.
Eccentri c runs on two doubl e r ow spheri cal rol l er beari ngs
supported by the stati onary mai n shaft.
To r emove the eccentr i c and gear assembl y, r emove hood,
and r emove the connecti n r od caps. Be sure caps are marked
so they can be repl ace d I n thei r ori gi nal posi ti on. Keep
shi ms i n thei r ori gi nal posi ti on.
Remove cl amps that hol d the mai n, or eccentr i c . aft to
frame. Be sure cl amps are i denti fi ed so they can be r etur ned
to thei r ori gi nal posi ti on.
l i ft the eccentr i c assembl y from the frame. Remove the
mai n beari ng retai ner pl ates from each end of the eccen-
tri c and dri ve the shaft out wi th a bl ock of wood and a
hammer.
Beri ngs are a sl i p fi t on the shaft and a l i ght press fi t i n
the beari ng bor e i n the eccentri c.
Beari ngs are to be repl aced i f wor n excessi vel y or i f darnaged.
A darnaged beari ng wi l l be noi sy. Do not r emove pr otecti ve
grease i n new beari ngs. I t wi l l not contami nate the crankcase
oi l .
When new beari ngs are to be i nstal l ed, be sure to repl ace
the rubber quad ri ng seal s i nsi de the bronze seal retai ners
pressed i nto the eccentr i c bor e just i nsi de the eccentr i c
beari ngs. These seal s bear on the shaft and pr event l oss
of oi l pressure to the eccentr i c cams and connecti ng rods.
19. MAI N GEARS After l ong wear the mai n gears can
be r ever sed by changi ng eccentr i c and gear assembl y end
for end, or by exchangi ng the gears on the eccentri c. i n
ei ther case i t i s al so necessary to change the jackshaft end
for end. When gear set i s r ever sed i t i s necessary to i nstal l
a new oi l pump dri ve pi ni on to match the opposi te spi ral
mai n gear. I t i s not possi bl e to move the oi l pump to oppo-
si te si de of the frame i n thi s pump.
i n a new pump the gears are mounted so the outer ends
of the teeth l ead. I f gears are r ever sed, the outer ends of
the teeth wi l l fol l ow.
Gears are l ocated on the eccentr i c fl ange b means of one
cap scr ew whi ch i s l arger than the rest. I t shoul d be i nsert-
ed fi rst, and al l cap screws ti ghtened evenl y and wi red
i n pai rs.
Lower the eccentr i c assembl y, wi th mai n shaft i nstal l ed,
i nto the frame after jackshaft has been i nstal l ed. Secur e
shaft to frame wi th saddl es. See torque tabl e on page 12
for pr oper ti ghteni ng of the saddl e stud nuts.
Reassembl e connecti ng r od caps i n ori gi nal posi ti on. Be
sure ori gi nal shi ms are i n pl ace. See tabl e on page 12 for
ti ghteni ng of the connecti ng r od bol t nuts.
Check crankcase for tool s or other parta and fi l l wi th new
oi l befor e repl aci ng hood,
20. PUSH RODS Push rods can be r emoved from the
crossheads by worki ng through handhol e pl ates i n the si des
of the frame and al so throu h the oi l stop openi ngs after
the oi l stop head assembl i es havebeen r emoved.
Page 10
Be careful not to damage the hi ghl y pol i shed surface on
whi ch oi l seal s bear.
push rods are chr ome pl ated and shoul dd be pr otected when
the pump i s pai ntecl . Pai nt wi l l damage oi l stop head seal s.
21. CROSSHEADS AND PINS Crossheads are of one-
pi ece constructi on wi thout removabl e shoes. They bear on
sl i des bor ed i n the frame.
Crossheads are equi pped wi th strai ght ful l -fl oati ng pi ns
secured each end by spri ng retai ners i n gr ooves near the
ends.
The retai ner ri ngs can be reached from the mai n hood
openi ng or through the crosshead i nspecti on pl ates on
the si des of the frame. I t wi l l be necessary to turn the ump
over to l ocate each crosshead for accessi bi l i ty whi l e r e-
movi ng the crosshead pi ns.
Crossheads may be r emoved by removi ng oi l stop heads,
push rods and crosshead pi ns. Sl i de the crossheads through
the oi l stop bores i n the frame and l i ft them cl ear. Be care-
ful l to pr otect the shoe surfaces from damage. al sO pr otect
the l ower sl i de i n the frame by pl aci ng a wooden bl ock
beneath the smal l end of the connecti ng rod.
I t i s necessary to r emove one outer crosshead befor e the
center one can be reached for removal .
22. OI L STOP HEADS Oi l stop heads keep crankcase
oi l wi thi n the frame. They al so keep mud and l i ner washi ng
water from enteri ng the crankcase.
Oi l stop packi ng consi sts of two i denti cal urethane seal s
mounted i n adaptors. They are not adjustabl e.
The i nner seal Li p i s poi nted i nward toward the crankcase
to stri p oi l from the push rod. The outer seal I i poi nts
f outward toward l i ner to stri p mud and/or water rom the
push rod. Be certai n seal s are pr oper l y l ocated.
The seal adaptors, wi th seal s i n them, can be sl i pped off
and on the push rods by removi ng the cl smp hol di ng pi ston
rods agai nst the push rods and separati ng the two fl anges.
DO NOT use a scr ewdr i ver or dri ft to separate the push
r od and pi ston r od fl anges. Turn the pump sl i ghtl y.
i t i s essenti al that oi l stop head seal s be repl aced at the
fi rst i ndi cati on of l eakage. Oil l eakage wi l l be i ndi cated
by oi l col l ecti ng on top of the l i ner washi ng water i n the
r eser voi r . I f ri water i s used for washi ng and run to a waste
area, i t i s di ffi cul t to check by above methocl .
I f oi l l eakage i s seri ous i t wi l l show up i n a l ower oi l l evel
i n the crankcase. i n thi s case oi l must be added to crank-
case as requi red unti l new oi l stop seal s can be i nstal l ed.
Leakage of mud and water i nto the crankcase wi l l be i n-
di cated by a mi l ky appearance of the crankcase oi l . I f
excessi ve, the mud can be detected by reachi n through
the oi l wi th the hand, or by drai ni ng out a smal l quanti ty
of oi l . Mud wi l l al so be seen bel ow the oi l stop heads on
i nsi de of crankcase through crosshead i nspecti on pl ate
openi ngs.
When mud i s found i n crankcase, oi l shoul d be changed.
Drai n and cl ean out crankcase befor e putti n i n the new
oi l . Repl ace mud scraper seal s i n oi l stop heads befor e
runni ng pump.
We recommend oi l stop head seal s be changed ever y si x
months of operati on, even through l eakage i s not evi dent.
3-1-605 Page 11
23. RECOMMENDED RUNNING CLEARANCES FEELER
Crosshead to Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jackshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crosshead Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Li nerto Eccentri c (On Hori zontal Centerl i ne) . . . . . .
Oi l Pump Pi ni on to Mai n Gear Backl ash . . . . . . . . . . . . . . . . . . .
Jackshaft to Mai n Gear-Backl ash . . . . . . . . . . . . . . . . . . . . . . . .
24. MANUFACTURI NG Fi tS ACTUAL
Jackshaft Beari ng ODi n Housi ng. . . . . . . . . . . . . . . . . . . . . . . . . .
Jackshaft Beari ng on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crosshead Pi n Bushi ng OD i n Connecti ng Rod . . . . . . . . . . . . . . . . .
Mai n Beari ng ODi n Eccentri c . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mai n Beari ng on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25. RECOMMENDED TORQUES
Cyl i nder to Frame Stud Nut (185 Lb. Man on4-1/2 Ft. Wrench) . . . .
Connecti ng Rod Bol t (185 Lb. Man on 2-1/2 Ft. Wrench) . . . . . . . . . .
Pi ston Rod Nut (185 Lb. Mari on 6Ft. Wrench) . . . . . . . . . . . . . . . .
Stuffi ng Box to Frame Stud Nut (185 Lb. Man on 3-1/4 Ft. Wrench) .
Li ner Cl amp Nut (185 Lb. Man on 3-1/4 Fr. Wrench). . . . . . . . . . . . .
Mai n Shaft Sadcl l e Stud Nuts (Two 185 Lb. Men OP 8 Ft. Wrench) . . .
I nches
Min.
.010
.002
.002
.0005
.008
.010
.010
.0003
Ti ght
.0003
Ti ght
.003
Ti ght
.0026
Ti ght
.0004
Ti ght
max
.018
.004
.003
.0015
.010
.020
.020
.0021
Loose
.0021
Ti ght
.005
Ti ght
.0008
Loose
.0015
Loose
Mi l l i meters
Mi n.
.254
.051
.051
.0127
.203
.254
.254
.0076
Tight
.0076
Tight
.076
Tight
.0660
Tight
.0102
Tight
Max.
.457
.102
.076
.0381
.254
.508
.508
.0533
Loose
.0533
Tight
.127
Tight
.0203
Loose
.0381
Loose
Ft. Lbs. kg-m Nom
800 111 1085
440 61 597
1110 153 1505
600 83 813
600 83 813
3000 415 4067
3-1-605 Page 12
Litho in U.S.A.
lM-6-82
GARDNER-DENVER
INDUSTRIAL MACHINERY DIVISION
1800 GARDNER EXPRESSWAY G QUINCY, ILLINOIS 62301
. .
SALES AND SERVICE OFFICES IN ALL PRINCIPAL
G (217) 222-5400
CITIES