Gardner Denver GD-3000 User Manual Download

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ECN 1058968

GARDNER DENVER

3-1-618 Revision D

April 2011

WELL SERVICING PUMP

MODEL

GD-3000

OPERATING AND
SERVICE MANUAL

Summary of Contents for GD-3000

Page 1: ...ECN 1058968 GARDNER DENVER 3 1 618 Revision D April 2011 WELL SERVICING PUMP MODEL GD 3000 OPERATING AND SERVICE MANUAL...

Page 2: ...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 distributor r...

Page 3: ...peration 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...

Page 4: ...Ordering Repair Parts i Foreword ii Index iv List of Illustrations v Section 1 Danger Notices 1 Section 2 Design Description and Specifications 9 Section 3 Preparation Operation and Maintenance 15 Se...

Page 5: ...ly Routine Maintenance Schedule 19 Oil Stop Head Seal Retainer and Crosshead Guide End Plate 24 Ordering Instructions Repair Parts i Performance Rating 14 Periodic Routine Maintenance Schedule 18 Plun...

Page 6: ...2 GD 3000 Power End 10 Figure 2 3 GD 3000 Power End Top View 11 Figure 2 4 GD 3000 Gear Reduction Unit 12 Figure 2 5 GD 3000 Fluid End 13 Figure 3 1 Lubricant Recommendations 17 Figure 4 1 Tightening...

Page 7: ...begin or continue operations when tired distracted or under the influence of alcohol or any type of prescription or nonprescription drugs The timely replacement of expendable parts and any other worn...

Page 8: ...e they have safe footing Fully engage the wedge to prevent it from disengaging violently from the cover as a blow is struck Wipe their hands and the hammer handle and maintain a firm grip on the handl...

Page 9: ...nnected 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 li...

Page 10: ...f 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 o...

Page 11: ...trols 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 system...

Page 12: ...eration and stop ongoing operation if flammable or explosive vapors are detected Hot surfaces sparks electric current or engine exhaust could ignite flammable or explosive vapors Each engine used as a...

Page 13: ...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 t...

Page 14: ...quality of design construction and safety since these components are among the most critical to the safe operation of high pressure liquid jetting blasting and cleaning equipment After you have selec...

Page 15: ...r software developed by American Gear Manufacturers Association The issue of personnel safety is the most important topic covered in this manual Therefore in the beginning of this manual the user is i...

Page 16: ...ques presents information useful for pump rebuilding and assembly including dimensional and tolerance data running clearances for all bearings and recommended fastener torques PUMP DESIGN The GD 3000...

Page 17: ...kle joint design is essentially standard but utilizes a large knuckle 7 and crosshead 13 5 thus allowing extremely high rod load 350 000 lbf See FIGURE 2 3 Also the pump has a drain pan to collect the...

Page 18: ...n the bottom of the frame in the center cylinder Oil passages at the forward part of the frame members allow the end cylinders to drain to the center Oil is also drained from three 1 crosshead drains...

Page 19: ...olt nuts The conventional valve over valve configuration offers field proven arrange ment in terms of valve and spring performance Improvements in the fluid end life come from increasing fluid cylinde...

Page 20: ...10 49 13 12 22 007 5 11 19 635 0 065 3 62 4 54 5 68 6 72 8 44 10 52 12 96 16 20 17 825 5 5 11 23 758 0 078 4 38 5 49 6 88 8 13 10 21 12 73 15 68 19 60 15 000 5 75 11 25 967 0 086 4 79 6 00 7 52 8 89 1...

Page 21: ...ges 5 Remove the breather and either plug or tape the opening 6 Coat the gear reducer input shaft and all extension rods with a heavy rust preventive 7 Plug drain holes at the bottom of the pump frame...

Page 22: ...nts In the past failure to meet these requirements has lead to pump damage because of restricted oil flow in the lube pump inlet Therefore the following guidelines developed as a result of long experi...

Page 23: ...o the volume to be pumped by the triplex pump so that there is no less than 40 psi charge when the triplex pump operates at its maximum flow The first startup and several hours of the pump run in are...

Page 24: ...pressure rating for 30 minutes 11 During this time 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 l...

Page 25: ...perform these tasks 4 Listen for any abnormal noise or rough operation which may indicate the need for fluid end maintenance such as changing valves or valve seats Due to very high pressures in the t...

Page 26: ...ps Petroleum 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...

Page 27: ...ile working on pump 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 replace...

Page 28: ...nger clamps piping connections and auxiliary equipment FIGURE 4 1 Tightening Sequence for Fluid End Nuts Plunger and Packing Replacement This service procedure can be performed with the fluid cylinder...

Page 29: ...nt twisting while loosening the stuffing box 4 Loosen the stuffing box using the stuffing box wrench 5 Carefully remove the stuffing box from the cradle area 6 Clean and oil the packing bore in the st...

Page 30: ...ng the engine inadvertently The power end service procedures deal first with major assemblies namely crosshead connecting rod crankshaft and knuckle joints and then describe how to access all individu...

Page 31: ...ice to the thread of the crosshead front half and lift off 14 Remove the thrust bearing 15 Remove the snap rings from the wrist pin 16 Remove the wrist pin while supporting the crosshead back half 17...

Page 32: ...the crankshaft from disengaging with the frame see Special Tools section of Parts Manual 8 Move the gearbox and the splined adapter to the service area Crankshaft Assembly 1 Remove the pump from the...

Page 33: ...he right side of the frame and the left end bearing and center left bearing out the left side of the frame 17 With bearing locks removed bearings may be driven out of bore with a hammer and brass or a...

Page 34: ...3 Clogged 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 proppe...

Page 35: ...settling 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...

Page 36: ...ise 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 Val...

Page 37: ...and 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...

Page 38: ...ons 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 cross...

Page 39: ...r Hammer 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 unev...

Page 40: ...Assembled in Journal Bearing Housing 7 755 7 759 Crosshead Guide Bore 302TLS100 13 500 13 502 Babbitt Crosshead Guide Bore 303TLS100 13 557 13 562 Crosshead without Babbitt 302TLS005M 13 487 13 489 C...

Page 41: ...sshead Guide to Pump Frame 3 4 10 200 Crankshaft Bearing to Pump Frame 3 4 10 290 Suction Manifold to Fluid End 7 8 9 320 Discharge Flange to Fluid Cylinder Nuts 1 1 8 12 1080 Gear Reducer to Pump Fra...

Page 42: ...to Purchaser whichever occurs first The exceptions are as follows 1 Power end is warranted for twelve 12 months from date of start up or eighteen 18 months from date of delivery to the Purchaser whic...

Page 43: ...o title the foregoing 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 o...

Page 44: ...breach of this warranty must be commenced within one year after the date upon which the cause of action occurred Any adjustment made pursuant to this warranty shall not be construed as an admission b...

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