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Gardner Denver FXD - 10", Operating And Service Manual

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Gardner Denver FXD - 10

3–600    Page iii

TABLE OF CONTENTS

Introduction

i

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Repair Parts Ordering Instructions

i

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Foreword

ii

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List of Illustrations

iii

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Index

iv

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Danger Notices, Section 1

1

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Installation and Operating Instructions, Section 2

7

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Routine Maintenance & Service Instructions, Section 3

12

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Dimensions & Running Clearances, Section 4

15

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TroubleShooting, Section 5

19

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Warranty

Last Page

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List of Illustrations

Figure  1

Crankcase Oil Requirements

7

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Figure  2

Lubrication Fill Rate

8

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Figure  3

Packing Type Piston

8

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Figure  4

Cup Type Piston

9

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Figure  5

Piston Textures

9

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Figure  6

Piston Rod

10

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Figure  7

Rotation of Eccentric

11

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Figure  8

Jackshaft Assembly

12

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Figure  9

Eccentric and Main Shaft Assembly

12

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Figure 10

Crosshead Pin Removal – FXX, FXD & FXE

13

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Summary of Contents for FXD - 10"

Page 1: ...GARDNER DENVER DUPLEX POWER PUMP MODELS FXF 5 FXG 6 FXX 8 FXD 10 FXE 10 OPERATING AND SERVICE MANUAL 3 600 6th Edition June 1997 ...

Page 2: ...pump Authorized distributor service technicians are factory trained and skilled 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 and OPI distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery ...

Page 3: ...esult in economical operation and minimum downtime 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 is used to indicate the presence of a hazard which can cause severe person al injury death or substantial property damage if the warning is ignored Caution is used to indicate the presen...

Page 4: ...ion 3 12 Dimensions Running Clearances Section 4 15 TroubleShooting Section 5 19 Warranty Last Page List of Illustrations Figure 1 Crankcase Oil Requirements 7 Figure 2 Lubrication Fill Rate 8 Figure 3 Packing Type Piston 8 Figure 4 Cup Type Piston 9 Figure 5 Piston Textures 9 Figure 6 Piston Rod 10 Figure 7 Rotation of Eccentric 11 Figure 8 Jackshaft Assembly 12 Figure 9 Eccentric and Main Shaft ...

Page 5: ...let or Suction Piping 7 Fluid Piston Rod Baffle 9 Fluid Piston Rod Packing 9 Fluid Pistons and Packing 8 Fluid Valves 10 Foreword ii Frame Oil Stop Head Packing 9 FXE Main Gear and Eccentric 13 Hammer Lug Fasteners Danger Notice 1 High Pressure Liquid Jetting Blasting and Cleaning Danger Notice 5 High Pressure Pistons for Abrasive Service 9 High Pressure Special Fluid Service 8 High Temperature Se...

Page 6: ...CTIONS SECTION 3 12 Service Abrasive High Pressure Pistons 9 Boiler Feed 8 Clean Oil or Petroleum Products 9 High Pressure Special Fluid 8 High Temperature 9 Low Pressure Water 8 Specifications Torque 18 Starting a New Pump 10 Storage of Pump Special Care 14 Suction or Fluid Inlet Piping 7 Torque Specifications 18 TROUBLESHOOTING SECTION 5 19 Valve Relief 7 Valve Seat Pulling Danger Notice 2 Valve...

Page 7: ...tions and instructions contained in these manuals If any of these documents are lost or become illegible they must be replaced immediately The danger no tices plus the operating and service manuals should be reread periodically by both operators and maintenance personnel to refresh their memories in safe procedures and practices Keep in mind that full operator attention and alertness are required ...

Page 8: ... by trained experienced operators who are physically and mentally prepared to devote full attention and alert ness to the moving and lifting operations An operator should be fully aware of the use capabilities and condition of both the equipment being moved and the equipment being used to move it Failure to follow safe and proper pump pump package or component lifting or moving procedures can lead...

Page 9: ...is charge line and not at the opposite end of the discharge manifold in a dead end connection The dead end may become clogged with solid material carried in the fluid which could prevent proper relief valve operation Never place a shut off valve or any other component between the pump discharge connection and the pres sure relief valve Make sure the pressure relief valve is installed so any pressu...

Page 10: ...r pump systems Block the crankshaft from turning and make certain that all pump drive motor or 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 discharge and pump lubricating sys tems for leaks Thoroughly investigate the cause for leakage and do not ...

Page 11: ...n and all electrical components and wiring must meet the current National Electrical Code for explosive atmosp heres These precautions must be taken to avoid possible per sonal injury death and or equipment damage from ex plosion fire or burns HIGH PRESSURE LIQUID JETTING BLASTING AND CLEANING Extreme caution must be exercised if any type of wand gun nozzle or any other pressure and flow directing...

Page 12: ...er connect any equipment to the system which has a rated or tested pressure capability be low 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 sh...

Page 13: ...visable to use an am ple size discharge line to prevent excessive friction The use of an air chamber is recommended and ample size chambers are available for all pumps RELIEF VALVE Pump must be protected from ex cess pressure by a discharge pressure relief valve The valve must be installed near the pump preferably in the opening provided for it in the discharge manifold on models where applicable ...

Page 14: ... fittings A reliable multipurpose FIGURE 3 PACKING TYPE PISTON grease NLGI Grade No 2 should be supplied to these with discretion Roller bearings WILL HEAT IF TOO MUCH GREASE is used especially if bearing is com pletely filled with grease FLUID PISTONS AND PACKING Four general types of fluid pistons and packings are used depending upon operating conditions or requirements The pumps are packed at t...

Page 15: ...g is standard for water oil and general service Maxi mum service ratings for this packing are 250 PSI and 250_ F Molded convex packing is standard for mud service Maximum rated service temperature is 180_ F Molded rubber and duck packing is standard for grout and cement service and optional for other services Maximum rated service temperature is 250_ F Rod packings should always be installed in a ...

Page 16: ...ving approximately one thread of the locknut over the relieved portion of the rod as a protection to the threads FLUID VALVES Valves are easily installed in their in dividual valve pots Care should be exercised to tighten the valve cover nuts as uniformly as possible tighten ing each nut a little at a time until all are tight Valve FIGURE 6 PISTON ROD seats and the bore in the deck must be perfect...

Page 17: ...3 600 Page 11 FIGURE 7 ROTATION OF ECCENTRIC PREFERRED ROTATION OF ECCENTRIC ...

Page 18: ...ushings are pressed on the jackshaft and need not be removed unless replacement is necessary The jackshaft can be lifted clear of the gear teeth and removed The jackshaft is not interchangeable end for end hence it must be reinstalled in the same way it was removed Installation of Jackshaft Oil Seals The jackshaft roller bearings are provided with a separate inner and outer oil seal The correct as...

Page 19: ...nd wood block The bearing cone and seal sleeve on the side opposite the tapped hole will slip off the shaft To Install Main Bearings For All Pumps 1 Install eccentric with gear teeth in correct position in frame 2 Install main shaft through opening in frame and through eccentric 3 Heat and press bearing cones to shaft 4 Install bearing cups There should be no space between the bearing cones and se...

Page 20: ...from Gard ner Denver Machinery Inc OPERATING SPEEDS AND PRESSURES See bul letins for operating speeds and pressures for type of service All displacements are theoretical with piston rod vol ume deducted For actual delivery deduct from 5 to 10 for slippage using 10 at maximum RPM Pressures are maximum permissible with rated maximum piston rod loads and MUST NEVER BE EXCEEDED While it is true that r...

Page 21: ...ameter Diameter Stuffing Box End End Model Type Inches mm Inches mm Inches mm Inches mm FXF ALL 4 x 5 101 6 x 127 0 15 16 23 8125 1 3 4 44 45 2 1 16 52 3875 FXG ALL 5 x 6 127 0 x 152 4 1 25 4 1 13 16 46 0375 2 3 8 60 325 FXX D H 5 x 8 127 0 x 203 2 1 1 2 38 1 2 1 2 63 5 1 1 8 28 575 FXD M Q or or 1 1 2 38 1 2 1 2 63 5 3 1 8 79 375 FXE U 5 x 10 127 0 x 254 0 B C 5 x 8 127 0 x 203 2 1 1 2 38 1 2 1 2...

Page 22: ...e occurs b CONNECTING ROD LINER TO ECCENTRIC Actual 011 022 279 559 009 017 229 432 Feeler Gauge 010 021 254 533 008 016 203 406 Condemnable when liner knocks or clearance equals 040 1 016 035 889 c CROSSHEAD PIN Feeler Gauge 0015 002 038 051 0015 002 038 051 Condemnable Replace pressed in type bushings when a 006 152 mm feeler gauge can be inserted between the pin and bushing or when the crosshea...

Page 23: ...s b CONNECTING ROD LINER TO ECCENTRIC Actual 007 015 178 381 006 014 152 356 Feeler Gauge 006 014 152 356 005 013 127 330 Condemnable when liner knocks or clearance equals 030 762 030 762 c CROSSHEAD PIN Feeler Gauge 0005 0010 0127 0254 0005 0010 0127 0254 Condemnable Replace pressed in type bushings when a 006 152 mm feeler gauge can be inserted between the pin and bushing or when the crosshead p...

Page 24: ...luid Cylinder 590 81 6 Head Stud Nut Fluid Cylinder Liner 25 3 5 25 3 5 25 3 5 25 3 5 Set Screw Suction Manifold to 260 36 0 Fluid Cylinder Discharge Manifold to 260 36 0 Fluid Cylinder Suction Manifold 260 36 0 260 36 0 260 36 0 150 20 7 Flange Nut Discharge Manifold 260 36 0 800 110 6 150 20 7 Flange Nut Piston Rod Nut 525 72 6 525 72 6 525 72 6 260 36 0 Slush Proof Rod FXE ONLY ft lbs kg m Main...

Page 25: ...e in drive c High back pressure d Piston rings in fluid end binding e Pistons improperly packed f Valves not holding g Leakage past fluid piston rings h Leakage past liner packing i Liners worn PUMP LOSES CAPACITY AFTER STARTING a Leaky suction line b Suction lift too great c Entrained vapors in the fluid especially if fluid is warm PUMP VIBRATES a Fluid pistons improperly packed b Foundation not ...

Page 26: ...bor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedules caused by but not limited to location or inaccessibility of the equipment or labor provided by unauthorized ser vice personnel is not provided for by this warranty All costs of transportation of product or parts claimed not to be as warranted and of repaired or repl...

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