Gardner Denver HD-2250 Operating And Service Manual Download

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ECN 1058968

GARDNER DENVER

300THD996 Revision D

April 2011

HD-2250

TRIPLEX PUMP

OPERATING AND

SERVICE MANUAL

Summary of Contents for HD-2250

Page 1: ...ECN 1058968 GARDNER DENVER 300THD996 Revision D April 2011 HD 2250 TRIPLEX PUMP OPERATING AND SERVICE MANUAL...

Page 2: ...n 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 ref...

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: ...s For 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...

Page 5: ...Performance Rating HD 2250 13 Periodic Routing Maintenance Schedule 18 Plunger Packing Lubrication 16 Plunger Packing Lubrication Recommendation Chart 19 Plungers and Packing Replacement 21 Power End...

Page 6: ...10 Figure 2 3 HD 2250 Power End Section B B 11 Figure 2 4 Fluid End 12 Figure 3 1 Power End Lubricant Recommendations 16 Figure 4 1 Fluid End Stay Rods and Heavy Hex Nuts 21 Figure 4 2 Packing Assemb...

Page 7: ...when 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...

Page 8: ...od condition Replace any of those parts which are cracked damaged or badly worn Wear safety shoes and goggles Check to insure they have safe footing Fully engage the wedge to prevent it from disengagi...

Page 9: ...lders Package units should be lifted with spreaders connected to the lifting attachments normally built into the package unit support skid Packages too large to lift as fully assembled should be separ...

Page 10: ...rect 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 open Check all fluid end discharge s...

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: ...ng If the pumped fluid releases harmful explosive or flammable vapors the covers must be vented to conduct the fumes away from the pump unit to a non hazardous area Before beginning pumping operations...

Page 13: ...e 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...

Page 14: ...orated in their products After careful study of various manufacturers products we recommend that only those wands nozzles guns connections and hose etc be considered for purchase that you judge to off...

Page 15: ...FIGURE 2 1 HD 2250 PUMP Page 9...

Page 16: ...eloped by American Gear Manufactures Association The HD 2250 has a proven track record as a reliable trouble free pump The Issue of personnel safety is the most important topic covered in this manual...

Page 17: ...pump will vary slightly due to the various accessories but will not exceed 12 650 pounds Materials used in the power end have been selected to provide long life and meet the rigorous demands required...

Page 18: ...bit coating for improved break in characteristics The wrist pin which is made of heat treated ground high strength alloy steel serves only to return the crosshead assembly It bears none of the thrust...

Page 19: ...d There is one drain hole on the bottom of the power frame User plumbing will direct drain oil flow back into the lube sump FLUID END FIGURE 2 4 The conventional valve over valve configuration offers...

Page 20: ...50 1 65 165 14941 248 14010 330 10508 545 6368 4 00 1 31 130 18909 196 17732 261 13299 431 8060 3 75 1 15 115 21515 172 20175 229 15131 378 9170 Brake Horsepower 1600 2250 2250 2250 Based on 90 Mechan...

Page 21: ...g or tape the opening 6 Coat the gear reducer input shaft and all exposed bare metal with a heavy rust preventive 7 Plug drain holes at the bottom of the pump frame at the rear of the pump and the gea...

Page 22: ...ore the following guidelines developed as a result of long experience should be adhered to closely 1 The oil flow velocity through the suc tion piping should not exceed 2 ft sec or 0 6 m sec 2 At maxi...

Page 23: ...The first startup is performed at the factory during the acceptance tests as a part of quality assurance procedure However the new pump break in period process may continue for the first 80 100 hours...

Page 24: ...page 12 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 minute at the following loads 40 of full rated...

Page 25: ...ndicate the need for fluid end maintenance such as changing valves or valve seats Due to very high pressures in the triplex pump fluid end worn valves and seats should be changed as soon as possible t...

Page 26: ...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 27: ...and lifting devices should be used while working on pump FLUID END SERVICE This discussion starts with the description of steps necessary for removal and installation of the fluid cylinder assembly a...

Page 28: ...Cylinder Head sequence These nuts must be kept tight Under torqued nuts will lead to thread fatigue failure of the stay rods 6 Re install the plunger clamps piping connections and auxiliary equipment...

Page 29: ...4 to 5 1 4 7 16 5 1 2 to 6 3 4 1 2 7 larger 5 8 Movement tolerance 1 16 SuperBolt Style Covers Removal Jackbolts must be unloaded gradually If some jackbolts are unloaded prematurely the remaining ja...

Page 30: ...he suction cover retainer nut with the appropriate male hex wrench 2 Remove the suction cover with a threaded slide hammer type puller 3 If equipped open the hinged cover on the top of the crosshead h...

Page 31: ...e performed with the fluid cylinder on the pump Before starting make sure that special tools required for this procedure are available For part number of the tools see Parts Manual WARNING Never try t...

Page 32: ...emove the plunger clamps and slide the plungers forward 4 Remove the Oil Stop Head retainer cap screws and remove the Head 5 Remove roto seals and oil hoses from gear covers 6 Remove input seal housin...

Page 33: ...The crosshead guides or slide should be replaced if excessively worn or damaged See CLEARANCES pg 33 2 If the crosshead guides must be replaced it is recommended that it be done either by Gardner Den...

Page 34: ...hould come up and over the top of the pump out to the centerline for easy balanced lifting of the crankshaft This tool must be capable of lifting the crankshaft in a horizontal position 8 The cranksha...

Page 35: ...against the bearing race as severe damage to the bearings could occur WARNING When reassembling the crankshaft assembly make sure to follow these steps 1 Pack the outer races in dry ice before assemb...

Page 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...bled in Bearing Housing 7 254 7 259 Crosshead Guide Bore 9 877 9 880 Crosshead OD 9 860 9 855 Wristpin Dia 2 500 2 499 Wristpin Bushing Bore 2 503 2 505 RECOMMENDED RUNNING CLEARANCES ACTUAL New in Ma...

Page 43: ...sing 3 4 10 160 Extension Rod to Crosshead 3 1 4 8 1200 Conn Rod to Bearing Housing Lock Nuts 7 8 9 340 Fluid End Suction Manifold 7 8 9 340 Discharge Flange to Fluid Cylinder Nuts 1 8 475 Conn Rod Be...

Page 44: ...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 45: ...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 46: ...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 47: ...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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