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vehicles.    A  broken,  cut  or  otherwise  burst 
hose can release pressurized fluid that may 
cause 

personal 

injury, 

death 

and/or 

equipment damage.  
 
High  pressure  fluid  from  hand  held  or  hand 
directed pressure and flow directing devices 
may  overpower  an  operator’s  ability  to 
control  or  direct  the  device,  which  could 
lead  to  personal  injury,  death  and/or 
equipment  damage.    The  operator  must 
brace against the backward thrust of a hand 
held device.  In addition, a safety harness or 
safety net must be used when working in an 
area  where  the  operator  could  be  injured  in 
a  fall.    Stand  to  the  side  of  any  tubing  or 
containers  being  sprayed  to  avoid  back 
spray and never operate a hand held device 
above shoulder level.  
 
Never  direct  the  pressurized  fluid  stream at 
yourself or any other person, control valves, 
the  pump, pump drive, suction or discharge 
systems.    The  pressurized  stream  can 
cause  serious  personal  injury  or  death  and 
can  also  change  valve  or  control  settings 
which  could  dangerously  increase  the 
delivery  pressure  to  the  pressure  and  flow 
directing device. 
 
When  operating  a  pressure  and  flow 
directing  device,  use  only  equipment  which 
automatically  shuts  off  flow  when  an 
operator  releases  hand  or  foot  pressure  on 
the  pressurized  flow  trigger  control  to 
prevent injury if the operator is overpowered 
or becomes disabled. 
 
Check  to  insure  this  automatic  shut-off 
equipment  is  operating  properly  before 
every  use  and  never  circumvent  the 
automatic  shut-off  for  any  reason  or by any 
means when operating the equipment. 
 
When  operating  any  type  of  high  pressure 
liquid  jetting,  blasting  or  cleaning  devices, 
the  operators  must  always  wear  protective 
clothing  including,  but  not  limited to, a hard 
hat with full face visor, heavy duty rain coat 
and  pants,  boots  with  nonskid  sole  and 
safety  toe,  rubber  gloves  with  rough  grip 
surface and ear noise protection. 
 

Full  operator  attention  and  alertness  are 
required  when  operating  this  equipment  to 
avoid 

personal 

injury, 

death 

and/or 

equipment  damage.    The  operators  should 
take  frequent  rest  breaks  and  cease 
operations  when  they  become  tired  or 
distracted. 
 
Before  the  equipment  is  started,  the  work 
area  must  be  inspected  and  properly 
prepared  to  avoid  personal  injury,  death, 
and/or  damage  to  equipment.    Make  sure 
the  work  area  is  checked  for  hazardous 
fumes,  has  adequate  ventilation  for  engine 
exhaust and sufficient drainage for released 
fluid.    Check  the  work  area  for  electrical 
equipment,  connections,  outlets, fixtures, or 
lines.  If any are present they must be made 
water tight and the electrical power to these 
devices  must  be  shut  off  to  avoid  electrical 
shocks  from  fluid  contact.    The  work  area 
should  be  clearly  marked  and  roped  off  to 
keep unauthorized people and vehicles from 
entering.  Remove all loose parts, tools and 
equipment  from  the  work  area  before 
beginning operation. 
 
All  pressure  containing  devices  including 
wands,  nozzles,  guns,  hoses,  connections, 
etc.,  should  be  regularly  checked  for 
condition.    These components should all be 
tagged with their tested pressure capabilities 
together 

with 

the 

date 

testing 

was 

performed.    Always  be  aware  of  the 
pressure  level  in  the  system  and  never 
connect  any  equipment  to  the  system 
which  has  a  rated  or  tested  pressure 
capability  below  the  system  operating 
pressure.
    The  equipment  must  be  shut 
down  and  the  system  pressure  released 
before  changing  or  disconnecting  wands, 
nozzles,  guns,  hoses,  connections  or  any 
other pressurized system components. 
 
All  pressure  containing  devices  including 
wands,  nozzles,  guns,  connections,  etc., 
plus  all  automatic  shut-off,  pressure  and 
control  equipment  should  be  treated  with 
care.  Protect them from damage by people, 
objects  and  vehicles.    Never  lay  them  in 
dirt,  mud,  ice  or  other  loose  material  that 
could plug the fluid opening or interfere with 
their  operation.    Never  use  the  wand, 

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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