Price $5.00

3-1-605Ist Edition

PAH

TRIPLEX PUMP

31-605

n~ ~ GARDNER-DENVERCOOPERINDUSTRIES INDUSTRIAL MACHINERY DIVISION

Gardner-Denver (the “Company”) warrants its products only

as follows:

GENERAL PROVIS1ONS AND LIMITATIONS

The Company warrants to each original retail purchaser

(“Purchaser”) of its new products from the Company or

its authorized distributor that such products are, at the

time of delivery to the Purchaser, made with good material

and workmanship, provided that no warranty is made with

respect to:

1.

2,

3.

4.

5.

Any product which has been repaired or altered in

such a way, in the Company’s judgment, as to affect

the product adversely.

Any product which has, in the Company’s judgment,

been subject to negligence, accident, improper storage,

or improper installation or application.

Any product which has not been operated or main-

tained in accordance with normal practice and with

the recommendations of the Company.

Components or accessories manufactured, warranted

and serviced by others.

any reconditioned or prior owned product.

Claims for items described in (4) above should be submitted

directly to the manufacturer.

The Company’s obligation under this warranty is limited to

repairing or, at its option, replacing, during normal business

hours any part which in its judgment proved not to be as

warranted within the applicable Warranty Period. During the

first 90 days after start-up, not to exceed 120 days after

delivery, a new part or a repaired part along with the labor

for installation ofsuchnew orrepaired part will be provided.

Such parts and labor will be provided without charge to the

user during normal working hours at the Company’s or

authorized distributor’s service facility. All costs of trans-

portation of product or parts claimed not to be as warranted

and of repaired or replacement parts to or from such service

facility shall be borne by the Purchaser. The Company may

require the return of any product or part claimed not to be

as warranted to one of its facilities as designated by Company,

transportation prepaid by Purchaser, to establish a claim

under this warranty.

Replacement parts provided under the terms of this warranty

are warranted for the remainder of the Warranty Period of

the product upon which installed to the same extent as if

such parts were original components thereof,

GARDneR-DENVER

TRIPLEX AND QUINTUPLE PUMPS

WARRANty PERIOD

Except for the products or components listed below, the

Warranty Period for all products is 1,250 hours of operation

or three months after start-up, not to exceed 120 days after

delivery to Purchaser, whichever occurs first. The exceptions

are as follows:

Power end is warranted for 12 months from date of

start-up or 18 months from date of delivery to the

Purchaser, whichever occurs first.

Fluid end is conditionally warranted on pro-rata basis for

three years from date of delivery to the Purchaser.

Expendable fluid end parts, including valves, valve parts,

liners and pistons, are not covered by this warranty due

to variable abrasive nature of material pumped.

DISCLAIMER

THE COMPANY MAKES NO OTHER WARRANTY OF

ANY KIND WHATSOEVER EXPRESSED OR IMPLIED

AND ALL WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY

DISCLAIMED BY THE COMPANY. THE COMPANY

SHALL IN NO CASE BE SUBJECT TO ANY OTHER

OBLIGATIONS OR LIABILITIES WHATSOEVER WITH

RESPECT TO PRODUCTS OR SERVICES MANUFAC-

TURED OR FURNISHED BY IT OR ANY ACTS OR

OMISSIONS RELATING THERETO. THE REMEDY PRO-

VIDED UNDER THIS WARRANTY SHALL BE THE SOLE,

EXCLUSIVE AND ONLY REMEDY AVAILABLE TO PUR-

CHASER. UNDER NO CIRCUMSTANCES SHALL THE

COMPANY BE LIABLE FOR ANY SPECIAL, INDIRECT,

INCIDENTAL OR CONSEQUENTIAL DAMAGES, EXPEN-

SES, LOSSES OR DELAYS HOWSOEVER CAUSED.

NO statement, representation) agreement or understanding,oral or written, made by any agent, distributor, representative,

or employee of the Company which is not contained in this

Warranty will be binding upon the Company unless made in

writing and executed by an officer of the Company.

This warranty shall not be effective as to any claim which

is not presented within 30 days after the date upon which

the product is claimed not to have been as warranted. Any

a. tion for breach of this warranty must be commenced

within one year after the date upon whichch the cause of

action occurred.

Any adjustment made pursuant to this warranty shall not be

construed as an admission by the Company that any product

was not as warranted.

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TABLE OF CONTENTS

WARranTY . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . ...2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . ...3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . ...3

Suction Piping . . . . . . . . . . . . . . . . . . . . . . ...3

Relief Valve . . . . . . . . . . . . . . . . . . . . . . ...3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . ...3

Starting aNew Pump . . . . . . . . . . . . . . . . . ...3

Operation . . . . . . . ...+

SECTIONAL VIEW OF PUMP

SERVICE INSTRUCTIONS –

Cylinder . . . . . . . . . . . .

. . . . . . . . ...+ . . . . . 4

. . . . . . . . . . . . . . . . . 5

FLUID END . . . . ...6

. . . . . . . . . . . . . . . . . 6

valve s. . . . . . . . . . . . . . . . . . . . . . . . . . ...6

Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Plunger Stuffing Box Packing.. . . . . . . . . . ...7

Lubricator . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Piston Liners and Liner Clamps. . . . . . . . . . . . . 7

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . ...7

Piston Washing System . . . . . . . . . . . . . . . . ...7

SERVICE INSTRUCTIONS – POWER END . . . . . . 9

JackShaft . . . . . . . . . . . . . . . . . . . . . . . . . ...9

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . 10

Eccentric and Bearing Assembly . . . . . . . . . . . 10

Main Gears, . . . . . . . . . . . . . . . . . . . . . . . . . 10

Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Crossheads and pins . . . . . . . . . . . . . . . . . . . . 11

Oil Stop Heads . . . . . . . . . . . . . . . . . . . . . . . 11

Recommended Running Clearances. . . . . . . . . . 12

Manufacturing Fits . . . . . . . . . . . . . . . . . . . . . 12

Recommended Torques . . . . . . . . . . . . . . . . . . 12

3-1-605 Page 2

OPERATING AND MAINTENANCE INSTRUCTIONSFOR PAH TRIPLEX PUMP

INSTALLATION

1. LOCATION – The pump should be installed as closeto the fluid supply and as low as possible. Whenever pos-sible, ample space should be provided around the pumpto facilitate inspection and adjustment, with particular atten-tion being given to the space required for removal andinstallation of jackshaft, eccentric, packing etc.

The drive must be accurately aligned pump properly leveledand securely fastened to foundation or base.

Pump must have a positive suction head, 10 foot (3048 cm)minimum. Maximum allowable temperature of fluid handledis 200° F. (93° C.).

2. SUCTION PIPING – Suction pipe (or hose if used)should be the full size of the suction opening. If for anyreason the suction line is of greater length than usual, thenext larger size should be used. A long horizontal suctionline should slope up toward the ump at uniform gradeso that air pockets are eliminated. Suction line must beabsolutely tight as any sir leaking into the line will reducethe capacity of the pump. If it is necessary to have bendsin the suction line, they should have long radius sweeps.

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

3. RELIEF VALVE – The pump must be protected

should be installed near the pump,

safety valve and the pump cylinder. The relief valve shouldbe set to operate at approximately 1-1/4 times the dischargepressure.

4. LUBRICATION – The power end is lubricated byoil within the crankcase. Gear oil API Service Classification“GL-4” SAE 90 is recommended. Essential additives foroil are rust, foam and oxidation inhibitors.

in freezing weather, warm oil before starting pump. Itis also recommended that a cold pump be brought up tospeed gradually, if possible.

Crankcase capacity is 30 U.S. gallons (113.6 liter).

Oil must be added as required to maintain the level totop of the oil level gauge on the side of the frame.

Time between oil changes depends on local or operatingconditions. ordinarily, if the crankcase is kept closed,it should not be necessary to change oil more often thanonce in 1000 working hours. The pressure auge must

hbe watched and if it shows lack of pressure, t e oil levelshould be checked. Oil should be changed if found to bedirt . The screen on the suction of the circulating pump

hmig t be stopped up so the pump cannot get sufficientoil to maintain pressure. This screen should be examinedat rather frequent intervals and thoroughly cleaned. Itcan be removed without draining the oil from the crank-case.

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When overhauling pump , check all oil connections andh;clean all lines thoroug y. The oil relief valve should also

be inspected.

If pump is to be stored or shut down for an extended periodand if oil regularly used does not contain an additive forrust prevention drain the oil from the crankcase and addan oil base rust preventative, then turn pump over a fewtimes to coat working parts. This will protect the powerend parts against damage by rust. Before pum is againplaced in operation, drain crankcase and fill with new oil.

Oil pump is the gear-driven rotary type pump which protides faltered oil under pressure to connecting rod linersand crosshead pin bushings. Crossheads and guides arelubricated by flood from gear. The pump is reversible andwill deliver oil regardless of the direction of rotation. Allthe oil pumped is filtered before it goes to the bearings.

It is recommended that an independently driven oil pump,driven at a constant speed, be used on well servicing tits.

Oil Filter – A replaceable element oil filter is located insidethe pump crankcase. Filter mounting flange is on the out-side, making it possible to replace the element by removinend plate. only the oil within the filter case will be spilledwhen element is withdrawn.

Filter element should be replaced each time crankcase oilis changed or every 1000 hours.

Filter element is protected from excessive internal oil pres-sure by a relief valve between it and the oil pump. Reliefvalve setting is 110 PSIG (7.73 kg/cm2 ),

Oil flows through the oil titer before going through theheat exchanger.

Heat Exchanger (Optional Equipment) – A bronze heatexchanger can be provided to keep crankcase oil tempera-ture at 160° F. (710 C ) by means of an automatic watercontrol valve.

5. STARTING A NEW PUMP – Pumps are shi pedfrom the factory without oil in the crankcase. The oodshould be removed and the power end examined and cleanedif necessary. The pump may have been in storage or in theyard for some time and as a consequence, dirt or rust fromcondensation may have formed in the crankcase. AlSO,parts may have been robbed from the pump during storageand not replaced. Drain all water accumulated in the bottomof the crankcase, check nuts and screws and tighten ifnecessary. Fill crankcase with oil of proper grade and toproper level.

WELL SERVICING PUMPS MUST BE DRIVEN ONLYIN THE DIRECTION INDICATED. Other PAH pumpscan be driven in either direction but the indicated directionis recommended because the crosshead load will be carriedon the bottom guide, resulting in more quiet operation andbetter lubrication.

The direction of rotation of the jackshaft is indicated by

Page 3

an arrow on the frame. To prevent excessive wear on thefluid pistons or plungers and packing when starting removethe discharge valve cover plates and discharge valves andprime the pump. PRIMING IS IMPORTANT! IT LUBRI-CATES PLUNGERS OR PISTONS AND LINERS. Pumpshould be started slowly and should be operated for severalhours with practically no discharge ressure. Check oil levelas it may be necessary to add a sm& amount of oil to com-pensate for that adhering to the walls of the crankcase andmovin parts, The pump may then gradually be brought up

ullto f speed and full working pressure. Watch for undueheating or abnormal noise in the working parts. Check alljoints in the suction line to be sure there are no air leaks.

Before starting a pump which has been idle for a long periodof time, drain any water due to condensation from crankcase

by removing the drain plug and replace when clean oilbegins to flow from the drain. Add oil to proper level. Itis recommended that fluid end of the pump be primed toprevent excessive wear on the plungers or pistons and linerswhen starting. PRIMING IS IMPORTANT! IT LUBRI-CATES PLUNGERS OR PISTONS AND LINERS.

Pump should always be started slowly, and with little pres-sure, after it has been idle or where it is on intermittentservice such as well servicing. This gives the oil a chanceto warm up and flow through all oil lines and bearings.This warm-up is especially important during cold weather,

6. OPERATION – The PAH pump should not be operated at speeds or pressures exceeding the values shownon the name plate.

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5

SERVICE INSTRUCTIONS

FLUJD

7. CYLinDER – Two different style cylinders are protided for the PAH pumps to suit the service. Both stylecylinders are the three-piece block type. Material is heattreated for ed alloy steel. The fluid end is provided withremovable bolted-on suction and discharge manifolds.

Cylinder is secured to the frame by high tensile strengthconnecting studs. It is important that nuts on these studsbe checked occasionally for tightness. A loose nut willcause a stud to break under pulsating load. See propertightening torque on page 12.

The connecting studs extend through the stuffing box orliner clamp flanges to clamp the stuffing boxes or linerstightly against the face of the cylinder.

B702

FIGURE 2. – BLOCK-TYPE FLUID CYLINDERFOR WATER FLOOD SERVICE

8. VALVES – In order to keep the pump in its bestoperatin condition, it is necessary to examine the suctionand discharge valves occasionally to see that excessive wearor cutting by the slush or mud has not impaired their effi-ciency. any worn or damaged parts should be replaced.

This is especially true with regard to the inserts. Standardinserts are made of urethane and are the part of the valvewhich should be changed most frequently. They are muchcheaper than the valves and seats, and if inserts are renewedas soon as they begin to fail, the more expensive steel parts

3-1-605

END

will last much longer. Routine inspection of valves everytwo or three days is recommended on drilling and wellservicing units.

To remove Water Flood Service Valves, remove the dis-charge valve cover stud nuts and valve covers. Removedischar e valve cage,

hspring and valve and pull the seat

from t e taper bore with a puller. Repeat this same procedure for the suction valves. The discharge valves are largerthan the suction valves to permit installing and remov-ing suction valves through the discharge valve deck in thecylinder.

To remove Drilling and Well Service Valves remove suctionand discharge cover locks and valve covers and the suctionvalve guide retainer and guide and lift valve and springfrom seat. The seat may be palled from the tapered borewith a puller.

NOTE: If a seat puller powered by a hydraulic jack isused, be certain to chain or tie the jack downas it will jump violently when valve seat lets go.

If it becomes necessary to resort to the use ofheat or a cutting torch to remove a valve seat,the services of a man experienced in this opera-tion is necessary.

Before putting new seats in the pump, the tapered borein the valve seat deck must be thoroughly cleaned of mudor slush with a wire brush. Wire brush should be used aroundthe bore rather than up and down. Wipe the bore clean anddo not use oil or grease. The bore must be clean and dry orseat may not seat properly.

Place the new seat in the bore. Use an old valve bumper ora block of hard wood and drive with a sledge to a snuginitial fit. The pressure load on the valve in operation willdrive the seat home. NOTE: Never reuse an old seat onceit has been removed forn a cylinder, as it may not jit solidlyin the valve deck.

Do not put a used valve assembly on a new seat unless itis in practically a new condition. Be sure to replace a doubt-ful insert to protect seat and bumper.

Replace the upper valve guide if worn (drilling and wellservice units only). Replace the valve spring if it is worn,corroded, distorted or below normal tension. Valves areprovided with stainless steel s rings for maximum oper-sting life. A broken spring will cause rapid wear of valveguides (where used) and s ould be replaced – It will alsocause wear on suction valve guide mounting lugs inside thecylinder.

It requires experience and judgement to determine if valveparts should be replaced or not. Valves are cheaper thandown time.

When installing valves put the gasket carefully in place inthe valve chamber and install cover plate. Be certain gasketis not twisted or extruded, On drilling and well service unitstighten valve cover lock securely by using a bar and hammer.On water flood units tighten each valve cover stud nut to

Page 6

the proper torque to preload studs to 400 foot-pounds(55 kg-m) (542 Nom). Tighten cage valve cage to seat 4to 6 turns to a torque of 120 foot-pounds (16.6 kg-m)(163 N-m) for suction and 140 foot-pounds (19.4 kg-m)(190 Nom) for discharge.

The life of the valves will be lengthened if the mud tanksare kept clean. Foreign objects can be caught under thevalves, thereby holding them open and causing rapid cuttingof the seats and valves.

9. PLUNGER – Water Flood and Well Servicing Units –To remove a plun er, remove coupling bolt and couplingwhich holds the plunger to the push rod. Turn the pumpover until the plunger is in the stuffing box as far as itwill go. Continue to turn pump till push rod is backedaway from plunger as far as it will go. Remove stuffingbox with plunger and packing in the box as a completeunit. Pull plunger out of packing. The packing can be in-stalled in the box over the plunger, but the preferredmethod is to install the packing, then grease the plungerand push through the packing. Tighten the gland as muchas possible. Keep gland tight to prevent movement ofpacking.

To replace the assembly in pump, reverse above procedure.

Pumps are equipped with plungers made of materials asrequired for the service. Hardened steel and cohnonoyplungers are available for the drilling and well servicingunits. Colmonoy plungers only are available for the waterflood pumps.

Tighten frame to cylinder and stuffing box studs to propertorque of 500 foot-pounds (69 k-m) (678 Nom).

10. PLUNGER STUFFING BOX PACKING – Plungerstuffing boxes are packed with non-adjustable packinThe stuffing box gland must engage at least three threadto hold the pressure of the pump.

Always install a complete set when renewing packing. Cleanstuffing box thoroughly before installing new packing.Install junk ring in bottom of stuffing box. Oil each ringthoroughly and install one at a time, beginning with the

hbottom adaptor ring. Make sure the lips of t e packingface the pressure. Tighten gland bolt as much as possible.

Be sure that the glands do not “back off’ while the pumpis operating. Lock in place with lock pins.

Keep packing lubricated at regular intervals by addingmultipurpose grease NLGI Grade No. 2 at the grease fit-tings located on the top of the stuffing boxes.

11. LUBRICATOR – A force-feed lubricator is availableas optional equipment to supply oil to the three stuffingboxes. Lubricator is mounted on a bracket over the frameand is driven by linkage connected to a crosshead extension.Oil is delivered to the tapped opening in each stuffing boxthrough copper tubing. Lubricator is equipped with a checkvalve at each outlet connection. Use a good grade of engineoil, API Service Classification “SC” SAE 30.

Provide flow of 6 to 8 dro s per minute to each stuffingbox by rotating the contro to increase or decrease, thentighten locknut:

12. PISTON LINERSliners are reinstalled or

AND LINER CLAMPS – Whenreplaced it is advisable to check

3-1-605

cylinder to frame stud nuts and tighten if necessary. Referto page 12 for proper tightening torques.

Nuts holding liner clam sin place should not be overtighten-ed as distortion of the linerclamp and liner bore may result.Recommended tightening torque is shown in table on page12.

Change size of pistons and liners as volume and/or pressurerequirements change.

Liners are replaced by removing the liner clamps. Theyshould be cleaned and oiled after removal to protect againstrusting during storage, so they can be used again if theyare in usable condition,

Pump liners are to be clean both inside and out when in-stalled. Also clean the liner clamp bore and lightly oil allsurfacea.

Use new gaskets when installing liners and be sure to clean allsurfaces against which the gaskets fit. Liners or fluid cylin-ders may be cut by leaking gaskets. if pistons are properlymaintained there will be lit e or no cutting of the liners.

13. PISTONS – Single-acting pistons are made up ofhspecial body fitted wit a special piston insert developed

for these single-acting pumps.

Piston, with piston rods, can be removed or installed throughsuction valve opening after upper valve guide is removed byturning it 900. Valve spring must also be removed.

It is recommended that a piston and rod assembly be keptready for replacement. This is a practical time saver.

14. PISTON ROD – Piston rods are manufactured ofhigh carbon steel. They are electrolytically plated to protectagainst corrosion. They are provided with a knurled sectionso rod can be held while tightening piston nut. It is impor-tant that piston rod nut be tightened to recommendedtorque shown on page 12.

Piston rod to piston fit is straight. piston fits against flangeon piston rod with an “O” ring gasket to prevent leakage.Removal of piston is a simple operation since it is not drivenon a taper. Keep piston rod to push rod clamps tight at alltimes to prevent damage to their flanges and pilots. DONOT use a screwdriver or cold chisel to separate the flanges.Turn the pump slightly or use a puller screwed onto pistonrod threads where they extend beyond piston nut.

15. PISTON WASHING SYSTEM – The piston washingsystem is vital to the satisfactory performance and life ,fpistons and liners. The complete system must be kept ingood operating condition. Washing fluid should be main-tained in good condition and should be replaced whencontaminated to the point where free circulation is impaired.This is of utmost importance and should be impressed uponall operators of the pump.

Water supply lines should be permanently attached to theprovided in the circulating pump suction lines

between thecirculating pump and the tank. Water is thenquickly available as a washing fluid or to flush out the linesby operating the proper valves in the piping system.

The piston washing fluid may be varied according to condi-tions and operator’s preference. Water makes a suitablewashing fluid under most conditions. Good results can be

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obtained using water with one-half gallon of soluble oil per be regulated by a valve in the discharge line of the centri-tank of water within the closed system. A light oil gives fugal circulating pump to prevent splashing and beinggood results under some conditions, and can be used under blown about by the wind. Besides making things messysevere freezing conditions. and wasting washing fluid this could result in dan erous

hconditions around the pump when using any of t e oilThe more fluid circulated, the better; however, it should based solutions.

3-1-605 Page 8

SERVICE INSTRUCTIONS

POWER

Remove hood and crosshead inspection plates for accessto working parts. Before working in inside of crankcase,it is necessary to drain the oil. oil pump mounting andpiping connections are below the oil level.

mark all parts during dismantling so they can be returnedto their original position during assembly.

16. JACKSHAFT – It is advisable to remove eccentricand gear assembly before attempting to remove the jack-shaft. Jackshaft bearings wiU not clear the gears.

FIGURE 3.

Remove all sheaves or other drive members from the jack-shaft. Support each end of shaft during removal.

Remove bearing retainer from inner end of bearing housing.Remove bearing end plate from each side of the pump. Re-move bearing housing from one side and pull jackshaft andbearing assembly through this opening. Opposite bearinghousing need not be removed from the frame.

3A K HAFT

,GASKET 8 SHIM

END

Jackshaft bearings are of the double spherical type with endthrust in both directions taken on the right hand bearing.Both bearings are identical.

The safest way to remove the bearings from the jackshaftis by the careful use of heat. Do not overheat to the pointwhere bearing is discolored.

When replacing “ackshaft bearings it is necessary to makea split disc to clamp on shaft and against inner face of theouter bearing race to hold race square with axis of beating.See detail in Figure 3.

The jackshaft bearings should be replaced if any of therollers or races show damage or if they are excessivelyworn. A noisy bearing indicates bearing darnage, requiringreplacement. Check clearances by inserting feeler gaugebetween the roller and inner race with bearing assembledon the shaft and in the housing. This check can be madewith the bearing assembled out of the pump. See recom-mended running clearances on page 12.

To mount new bearings, install split disc (Figure 3 onshaft as shown in Fi re 4. Heat bearing in oil to about300° F. (149° C.) an slip it on the shaft against the bear-ing shoulder and split disc. The shaft can then be reinstalledin the frame, followed by the eccentric assembly.

To reassemble the jackshaft in the pump, it is necessary toreverse the procedure of removal. The teeth of the inioncan mesh in only one direction, therefore, the jackshaftis not interchangeable end for end in the pump unless gearand eccentric assembly is also reversed. Reversal of thecomplete gear set is permissible after gear or pinion teethbecome badly worn. When gear set is reversed it is necessaryto install a new oil pump drive pinion to match the oppositespiral main gear.

Recommended direction of rotation of the pump provides

/e>/_-’ SPLIT DISC - USEDURING INSTALLATION

L1 -------1 \

R- OF BEARING ANDm-? “ HOUSING

‘d ERRETAINER

u

FIGURE 4. – JACKSHAFT BEARING

D74236

INSTALLATION

3-1-605 Page 9

that outer ends of gear and pinion teeth lead. This meansthat when viewing from the hood opening the outer endsof the gear teeth point upward toward the jackshaft andthe outer ends of the pinion teeth point toward the ear.

fGears may be reversed but the direction of rotation o theWELL SERVICING PUMP MUST NOT BE REVERSED.Inner ends of teeth will lead after gear set has been reversed.

After jackshaft is in place with the pinion in mesh withthe gear, install the bearing housings. The housing is to bestarted on the bearing and in the bore of the frame andlightly driven in. Be careful to keep dirt from bearingsdurin assembly. Be sure the gasket is on the housing. Longthreaded studs may be used to pull the housing into theframe bore. It is well to work both ends at the same timeafter they have been well started over the bearing outerrace. This will minimize end thrust on the gear teeth. per-manently bolt “ackshaft bearing housings and remove the

dsplit discs use for positionin bearings during assembly.When discs are removed inst the bearing inner retainer,with cap screws and locking wire, on the right hand sideof pump only.

The outer grease seals are to be placed in the bearing endplates after they are bolted to the bearing housings andframe. Coat inside of the oil seals liberally with bearinggrease. Each outer seal is to be installed with garter springto inside, toward bearing. Seal bears on a replaceable wearsleeve shrunk onto shaft to prevent wear under the seal,

17. CONNECTING RODS – The connecting rods aresplit and bolted together on shims used principally to absorbnormal factory manufacturing tolerances. If the eccentricassembly is to be removed from the frame, the connectingrods need not be unbolted. in this case the crosshead pinsmust be removed. Eccentric and rod assembly will lift outof the frame freely if left hand eccentric is positioneddirectly above the shaft.

Whether or not the connecting rods need be removed de-pends upon the nature of work being done on the pump.

Connecting rod caps can be removed in case it is desiredto remove eccentric assembly only in order to replace mainbearings.

The connecting rods are provided with high lead bronzeliners which bear against the eccentric. The liners are pre-cision made in identical halves and are secured by clampsheld to the connecting rod and cap by cap screws. Theycan be replaced by removing connectin rod caps, butwithout removing connecting rod body from the pump.

The shims between connecting rods and their caps canbe used to adjust liner to eccentric running clearance toa limited degree. in no instance should an adjustment

18. ECCENTRIC AND BEARING ASSEMBLY –IMpoRTANT: Be sure to remove oil pump drive pinonwhen removing or replacing eccentric and gear assemblyto avoid bending oil pump shaft when gear is moved.

Eccentric runs on two double row spherical roller bearingssupported by the stationary main shaft.

To remove the eccentric and gear assembly, remove hood,and remove the connectin rod caps. Be sure caps are markedso they can be replace d In their original position. Keepshims in their original position.

Remove clamps that hold the main, or eccentric . aft toframe. Be sure clamps are identified so they can be returnedto their original position.

lift the eccentric assembly from the frame. Remove themain bearing retainer plates from each end of the eccen-tric and drive the shaft out with a block of wood and ahammer.

Berings are a slip fit on the shaft and a light press fit inthe bearing bore in the eccentric.

Bearings are to be replaced if worn excessively or if darnaged.A darnaged bearing will be noisy. Do not remove protectivegrease in new bearings. It will not contaminate the crankcaseoil.

When new bearings are to be installed, be sure to replacethe rubber quad ring seals inside the bronze seal retainerspressed into the eccentric bore just inside the eccentricbearings. These seals bear on the shaft and prevent lossof oil pressure to the eccentric cams and connecting rods.

19. MAIN GEARS – After long wear the main gears canbe reversed by changing eccentric and gear assembly endfor end, or by exchanging the gears on the eccentric. ineither case it is also necessary to change the jackshaft endfor end. When gear set is reversed it is necessary to installa new oil pump drive pinion to match the opposite spiralmain gear. It is not possible to move the oil pump to oppo-site side of the frame in this pump.

in a new pump the gears are mounted so the outer endsof the teeth lead. If gears are reversed, the outer ends ofthe teeth will follow.

Gears are located on the eccentric flange b means of onecap screw which is larger than the rest. It should be insert-ed first, and all cap screws tightened evenly and wiredin pairs.

Lower the eccentric assembly, with main shaft installed,into the frame after jackshaft has been installed. Secureshaft to frame with saddles. See torque table on page 12for proper tightening of the saddle stud nuts.

Reassemble connecting rod caps in original position. Be

sure original shims are in place. See table on page 12 fortightening of the connecting rod bolt nuts.

Check crankcase for tools or other parta and fill with newoil before replacing hood,

20. PUSH RODS – Push rods can be removed from thecrossheads by working through handhole plates in the sidesof the frame and also throu h the oil stop openings afterthe oil stop head assemblies havebeen removed.

Page 10

Be careful not to damage the highly polished surface onwhich oil seals bear.

push rods are chrome plated and shoulddbe protected whenthe pump is paintecl. Paint will damage oil stop head seals.

21. CROSSHEADS AND PINS – Crossheads are of one-piece construction without removable shoes. They bear onslides bored in the frame.

Crossheads are equipped with straight full-floating pinssecured each end by spring retainers in grooves near theends.

The retainer rings can be reached from the main hoodopening or through the crosshead inspection plates onthe sides of the frame. It will be necessary to turn the umpover to locate each crosshead for accessibility while re-moving the crosshead pins.

Crossheads may be removed by removing oil stop heads,push rods and crosshead pins. Slide the crossheads throughthe oil stop bores in the frame and lift them clear. Be care-full to protect the shoe surfaces from damage. alsO protectthe lower slide in the frame by placing a wooden blockbeneath the small end of the connecting rod.

It is necessary to remove one outer crosshead before thecenter one can be reached for removal.

22. OIL STOP HEADS – Oil stop heads keep crankcaseoil within the frame. They also keep mud and liner washingwater from entering the crankcase.

Oil stop packing consists of two identical urethane sealsmounted in adaptors. They are not adjustable.

The inner seal Lip is pointed inward toward the crankcaseto strip oil from the push rod. The outer seal Ii pointsfoutward toward liner to strip mud and/or water rom thepush rod. Be certain seals are properly located.

The seal adaptors, with seals in them, can be slipped offand on the push rods by removing the clsmp holding pistonrods against the push rods and separating the two flanges.DO NOT use a screwdriver or drift to separate the pushrod and piston rod flanges. Turn the pump slightly.

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 in thereservoir. If ri water is used for washing and run to a wastearea, it is difficult to check by above methocl.

If oil leakage is serious it will show up in a lower oil levelin the crankcase. in this case oil must be added to crank-case as required until new oil stop seals can be installed.

Leakage of mud and water into the crankcase will be in-dicated by a milky appearance of the crankcase oil. Ifexcessive, the mud can be detected by reachin throughthe oil with the hand, or by draining out a small quantityof oil. Mud will also be seen below the oil stop heads oninside of crankcase through crosshead inspection plateopenings.

When mud is found in crankcase, oil should be changed.Drain and clean out crankcase before puttin in the newoil. Replace mud scraper seals in oil stop heads beforerunning pump.

We recommend oil stop head seals be changed every sixmonths of operation, even through leakage is not evident.

3-1-605 Page 11

23. RECOMMENDED RUNNING CLEARANCES – FEELER

Crosshead to Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jackshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crosshead Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Linerto Eccentric (On Horizontal Centerline) . . . . . .

Oil Pump Pinion to Main Gear – Backlash . . . . . . . . . . . . . . . . . . .

Jackshaft to Main Gear-Backlash . . . . . . . . . . . . . . . . . . . . . . . .

24. MANUFACTURING FitS – ACTUAL

Jackshaft Bearing ODin Housing. . . . . . . . . . . . . . . . . . . . . . . . . .

Jackshaft Bearing on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crosshead Pin Bushing OD in Connecting Rod . . . . . . . . . . . . . . . . .

Main Bearing ODin Eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25. RECOMMENDED TORQUES

Cylinder to Frame Stud Nut (185 Lb. Man on4-1/2 Ft. Wrench) . . . .

Connecting Rod Bolt (185 Lb. Man on 2-1/2 Ft. Wrench) . . . . . . . . . .

Piston Rod Nut (185 Lb. Marion 6Ft. Wrench) . . . . . . . . . . . . . . . .

Stuffing Box to Frame Stud Nut (185 Lb. Man on 3-1/4 Ft. Wrench) .

Liner Clamp Nut (185 Lb. Man on 3-1/4 Fr. Wrench). . . . . . . . . . . . .

Main Shaft Sadclle Stud Nuts (Two 185 Lb. Men OP 8 Ft. Wrench) . . .

Inches

Min.

.010

.002

.002

.0005

.008

.010

.010

.0003Tight

.0003Tight

.003Tight

.0026Tight

.0004Tight

max

.018

.004

.003

.0015

.010

.020

.020

.0021Loose

.0021Tight

.005Tight

.0008Loose

.0015Loose

Millimeters

Min.

.254

.051

.051

.0127

.203

.254

.254

.0076Tight

.0076Tight

.076Tight

.0660Tight

.0102Tight

Max.

.457

.102

.076

.0381

.254

.508

.508

.0533Loose

.0533Tight

.127Tight

.0203Loose

.0381Loose

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-DENVERINDUSTRIAL MACHINERY DIVISION

1800 GARDNER EXPRESSWAY ● QUINCY, ILLINOIS 62301. .

SALES AND SERVICE OFFICES IN ALL PRINCIPAL

● (217) 222-5400

CITIES