Gardner Denver C2500Q QUINTUPLEX User Manual Download

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ECN 1058968

GARDNER DENVER

300CMC996 Revision C

April 2011

WELL SERVICING PUMP

MODEL

C2500Q QUINTUPLEX

OPERATING AND

SERVICE MANUAL

Summary of Contents for C2500Q QUINTUPLEX

Page 1: ...ECN 1058968 GARDNER DENVER 300CMC996 Revision C April 2011 WELL SERVICING PUMP MODEL C2500Q QUINTUPLEX OPERATING AND SERVICE MANUAL...

Page 2: ...lled in pump maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your local authorized Gardner Denver distribut...

Page 3: ...tion and minimal downtime DANGER Danger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warn...

Page 4: ...ons For Ordering Repair Parts i Foreword ii Index iv List of Illustrations v Section 1 Danger Notices 1 Section 2 Design and Description 9 Section 3 Preparation Operation and Maintenance 14 Section 4...

Page 5: ...er Packing 16 Monthly Routine Maintenance Schedule 18 Oil Stop Head Seal Retainer and Gear Covers 23 Ordering Instructions Repair Parts i Periodic Routine Maintenance Schedule 17 Plunger Packing Lubri...

Page 6: ...ure 2 1 C 2500Q Quintuplex Pump 9 Figure 2 2 C 2500Q Gear Reduction Unit 11 Figure 2 3 C 2500Q Fluid End 13 Figure 3 1 Lubricant Recommendations 16 Figure 4 1 Fluid End Removal and Assembly 21 Figure...

Page 7: ...en operating high pressure pumping equipment Operators should not begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription dr...

Page 8: ...damaged or badly worn Wear safety shoes and goggles Check to insure they have safe footing Fully engage the wedge to prevent it from disengaging violently from the cover as a blow is struck Wipe their...

Page 9: ...to the lifting attachments normally built into the package unit support skid Packages too large to lift as fully assembled should be separated into smaller loads For these smaller loads the lifting d...

Page 10: ...ef pressure Any pipe line used to direct pressurized relief flow to another location such as a collecting tank is not blocked The discharge system is not blocked and all the discharge line valves are...

Page 11: ...engine start switches or starter controls are clearly tagged with warnings not to start the pump while repair work is in process Whenever the pump is operating continually monitor the entire suction d...

Page 12: ...he atmosphere all around the pumping site for the presence of flammable or explosive vapors Do not begin operation and stop ongoing operation if flammable or explosive vapors are detected Hot surfaces...

Page 13: ...s with rough grip surface and ear noise protection Full operator attention and alertness are required when operating this equipment to avoid personal injury death and or equipment damage The operators...

Page 14: ...se wands nozzles guns connections and hose etc be considered for purchase that you judge to offer the highest quality of design construction and safety since these components are among the most critic...

Page 15: ...and also all other applicable safety rules and regulations must be carefully observed The sections on Pump Design Description and Specifications describe the pump design list the pump specifications a...

Page 16: ...icity The connecting rods bolt to the conn rod bearing housings The conn rod bearing housings are accessible through the rear of the pump and the connecting rod crosshead assemblies through the nose o...

Page 17: ...rosshead slides This is repeated for the rest of the main bearing and crosshead components Oil is removed from the power end through a 4 drain connection in the bottom of the frame Oil passages in the...

Page 18: ...the packing nut or gland Plunger packing lube holes are provided in the fluid cylinder The EWS Fluid End is a forged alloy steel block is designed for severe applications The EWS utilizes heat treated...

Page 19: ...31 6100 4 2 17 217 17900 326 11800 544 7100 718 5350 4 5 2 75 275 14150 413 9350 688 5600 908 4250 5 3 40 340 11450 510 7550 850 4550 1121 3450 5 5 4 11 411 9500 617 6250 1028 3750 1357 2850 5 75 4 49...

Page 20: ...rust preventative will not clog the oil passages 5 Remove the breather and either plug or tape the opening 6 Coat the gear reducer input shaft and all bear metal with a heavy rust preventive 7 Plug d...

Page 21: ...ed pump size to minimize losses in the suction piping Lube Pump Suction Piping Sizing and Requirements In the past failure to meet these requirements has lead to pump damage because of restricted oil...

Page 22: ...will be required to charge the fluid end suction manifold The charge pump should be sized according to the volume to be pumped by the quintuplex pump so that there is no less than 50 psi charge when t...

Page 23: ...observe the suction vacuum gage reading oil pressure and temperature and check for leaks 12 Run the pump at 80 90 strokes per min at the following loads 40 of full rated load 30 min 60 of full rated l...

Page 24: ...triplex pump fluid end worn valves and seats should be changed as soon as possible to prevent washing them out with the pumped fluid 5 Check the plunger packing lubrication pump for proper operation I...

Page 25: ...etroleum EP 500 Summer or EP 300 Winter 10 F Shell Oil Co Torcula Oil 32 50 F Torcula Oil 100 20 F Torcula Oil 150 15 F Torcula Oil 320 10 F Sun Oil Co Rockdrill 500 Light 5 F Rockdrill 1000 Heavy 5 F...

Page 26: ...p FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly and proceeds to the removal and replacement of expendable...

Page 27: ...stay rods 6 Reinstall the plunger clamps piping connections and auxiliary equipment FIGURE 4 1 C 2500 Fluid End Plunger and Packing Replacement This service procedure can be performed with the fluid c...

Page 28: ...or cut a valve seat with a torch Severe damage to the fluid end may occur Before starting make sure that special tools required for this procedure are available For part numbers of the tools see the P...

Page 29: ...d pops POWER END SERVICE DANGER Before attempting to service the power end of the pump the following safety precautions must be observed 1 Shift the pump transmission into the neutral gear 2 Shut off...

Page 30: ...ment pins PILOT the halves together Do not damage pins 3 CAUTION Both halves are heavy 4 Remove half bearing with prying action 5 Rod half of bearing may be tapped on one edge with a rubber hammer or...

Page 31: ...d Removal and Installation page 20 3 Remove the oil stop head seal retainer and gear covers as described in Oil Stop Head Seal Retainer and Gear Covers page 23 4 Remove the crosshead assemblies as des...

Page 32: ...Page 26...

Page 33: ...ap rings and braze together in 3 or 4 places for strength WARNING Do not drive against rollers or bearing cage Drive only against the bearing race as severe damage to the bearings could occur WARNING...

Page 34: ...ogged suction line 3 Clean out line 4 Suction and or discharge 4 Remove the obstruction valves propped open Low Discharge Pressure 1 Worn or fluid cut valve 1 Replace valve assembly 2 Valve propped op...

Page 35: ...tling time in supply tank Reduce pump speed 10 Air entering suction line 10 Repair suction line 11 Air entering charging pump 11 Tighten or replace shaft packing or seal 12 Air entering or charge gas...

Page 36: ...transmitted to 11 See Excessive Valve power end Noise problem 12 Cavitation noise transmitted 12 See Cavitation Fluid to or causing shock loading in Knock or Hammer problem power end Excessive Valve N...

Page 37: ...sealing surface 4 Corrosion due to wrong 4 Determine and install correct stuffing box material stuffing box for pumped fluid 5 Stuffing box bore worn 5 Replace stuffing box Pumped Fluid In 1 Worn dam...

Page 38: ...Customer Service 5 Wrong size packing 5 Install correct size packing 6 Improper packing installation 6 Check installation procedure and install correctly 7 Excessive crosshead wear 7 Replace crosshead...

Page 39: ...mmer problem Stud Failures 1 Catastrophic failures 1 See Catastrophic Failures problem 2 Improper nut torquing 2 Check torque specifications and torque to correct values 3 Stud bending due to uneven 3...

Page 40: ...e Assembled in Bearing Housing 7 266 7 268 Crosshead Guide Bore 9 874 9 872 Crosshead OD 9 858 9 856 Wristpin Dia 2 500 2 499 Wristpin Bushing Bore 2 508 2 509 RECOMMENDED RUNNING CLEARANCES ACTUAL Ne...

Page 41: ...Page 34...

Page 42: ...Plunger Clamp Bolts 1 2 13 58 5 8 11 110 Pinion Bearing Housing 3 4 10 160 Intermediate Rod to Crosshead 3 4 10 160 Conn Rod to Bearing Housing Lock Nuts 3 4 10 180 Fluid End Suction Manifold 7 8 9 26...

Page 43: ...anty Period for all products is 1 250 hours of operation or three 3 months after start up not to exceed 120 days after delivery to Purchaser whichever occurs first The exceptions are as follows 1 Powe...

Page 44: ...regoing warranty is the sole and exclusive warranty of the Company The Company hereby extends other manufactures warranty or guaranties if any given to Company by such manufacturer but only to the ext...

Page 45: ...o this warranty shall not be construed as an admission by the Company that any product was not as warranted WARRANTY REQUESTS Products to be returned for warranty analysis shall be approved for return...

Page 46: ...representative or Gardner Denver Inc 4747 South 83rd East Avenue Tulsa OK 74145 PH 918 664 1151 800 637 8099 FAX 918 664 6225 www gardnerdenver com Specifications subject to change without notice Cop...

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