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3-1-618    Page 12 

 POWER  END  AND  GEAR  REDUCTION 
UNIT  LUBE  SYSTEM  
(FIGURE  2-2, 
FIGURE 2-3, and FIGURE 2-4,) 
 
Both  the  gear  reduction unit and power end 
have  individual  lube  oil  inlets.  The  power 
end inlet is located at the rear of the pump. 
The inlet is a 1-1/2” NPTF tee which divides 
the  lube  flow  between  the lube manifold for 
the  crosshead  guide  and  the  rotary  union. 
Pressurized  lubrication  for  each  crosshead 
is  delivered  from  the  lube  manifold  through 
the  underside  of  the  crosshead  guide.    An 
aluminum  cover  houses  the  rotary  union, 
which  is  attached  to  the  crankshaft. 
Lubrication  for  the  power  end  components 
comes  from  forced  lube  through  the 
crankshaft.  Lube  oil  enters  the  crankshaft 
and  first  lubricates  the #4 main bearing. Oil 
from  the  main  bearing  also  lubes  the  thrust 
bearing.  As  oil  reaches  the  first  crankshaft 
journal,  oil  exits  the  journal  oil  hole  and 
lubes  the  journal  and  journal  bearings, 
passes through the center of the connecting 
rod  to  the  wrist  pin  and  bushing.  It  then 
reaches the knuckle bearing and then to the 
crosshead.  This  is  repeated  for  the  rest  of 
the  main  bearing  cylinder  components.  Oil 
is  removed  from  the  power  end  through  a 
primary  4”  drain  in  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 located at  

the  forward  end  of  each  cylinder  in  the 
bottom of the crosshead guide. These three 
drains  are  combined  together  and  empty 
into the main drain external to the frame. 
 
The  gear  reduction  unit  has  one  inlet 
located on the upper input side of the offset 
section.  This  is  a  1-1/2”  NPTF  on  a  bronze 
“Y-type”  strainer  mounted  on  a  distribution 
block.  From  the  distribution  block  the  input 
and  output  gears  and  bearings  and 
planetary  section  are  lubricated  through  a 
spray bar, nozzle, and orifices.  
 
The  lube  oil  is  drained  from  the  gear 
reduction  unit  through  two  SAE  2”  4  bolt 
split  flange  drains  located  on  the  offset 
section  housing  and  one  1-1/2”  NPTF  drain 
on  the  transition  section  connected  to  the 
power frame. It is important that these drain 
hose  sizes  are  maintained  to  the  primary 
drain  and  include  as  few  restrictions  and 
direction  changes  as  is  practical.  Gear  unit 
heating  problems  are  most  often  related  to 
drain  restrictions  causing  buildup  of  oil 
inside  the  unit,  thus  generating  excessive 
heat. 
 
 

NOTICE

 

 

It  is  also  extremely  important  to 
maintain some downward slope in the 
entire  drain  system  back  to  the  lube 
reservoir

 

FIGURE 2-4 GD 3000 Gear Reduction Unit

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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