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15-600 Page 4
Worn or damaged hose assemblies should be
replaced immediately.
At least every six months
examine hose assemblies internally for cut or bulged
tube, obstructions and cleanliness. For segment style
fittings, be sure that the hose butts up against the
nipple shoulder, the band and retaining ring are
properly set and tight and the segments are properly
spaced. Check for proper gap between nut and
socket or hex and socket. Nuts should swivel freely.
Check the layline of the hose to be sure that the
assembly is not twisted. Cap the ends of the hose
with plastic covers to keep them clean until they are
tested or reinstalled on the pump unit. Following this
visual examination, the hose assembly should be
hydrostatically tested, on test stands having adequate
guards to protect the operator, per the hose
manufacturer’s proof test procedure.
Fluid end component inspections should be
performed more frequently than every six months
if pressures above 2,500 PSI are used in the
discharge system or if corrosive, flammable or
hot (over 110º F) fluids are being pumped.
Proper stuffing box packing selection is important for
safe pump operation. Contact a Gardner Denver
service representative for assistance in selecting the
proper packing before beginning operation.
Before starting the pump the first time and periodically
thereafter check the pump, suction and discharge
system fastener torques versus the values listed on
page 12 to insure proper tightness. Over and under
torquing can damage threaded pipes, connections
and fasteners, which may lead to component damage
and/or failure. Replace all components found to be
damaged or defective. On pumps equipped with
stuffing boxes, the gland must be engaged by at least
three (3) threads to hold the discharge pressure of the
pump.
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.
DANGER
Do not attempt to service, repair, or
adjust the plunger packing or otherwise
work on the pump while the unit is
operating. Shut off the pump drive
motor or engine and relieve the fluid
pressure in the pump suction and
discharge systems before any work or
investigation is performed on the pump
or pump systems.
Whenever the pump is operating, continually monitor
the entire suction, discharge and pump lubricating
systems for leaks. Thoroughly investigate the cause
for leakage and do not operate the pump until the
cause of the leak has been corrected. Replace any
parts which are found to be damaged or defective.
When a gasketed joint is disassembled for any
reason, discard the used gasket and replace it with a
new, genuine Gardner Denver gasket before
reassembling the joint.
Due to the high working pressures contained by the
fluid cylinder, discharge manifold and discharge
piping, welding on these components is not
recommended. If welding on the discharge system
cannot be avoided, only experienced, qualified
welders should be used. In addition, the welded part
should be hydrostatically proof tested in the shop with
water or hydraulic fluid to one and one half times
maximum discharge system working pressure, with
no observable fluid leakage, before the part is
reinstalled in the pump system.
In summary, high pressure fluid streams can possess
sufficient energy to cause personal injury, death
and/or equipment damage. These results can occur
either through direct contact with the fluid stream or
by contact with loose objects the fluid stream has
propelled, if the pump system is improperly used, or if
the fluid is misdirected, or allowed to escape from
defective or improperly maintained equipment.
FLAMMABLE, HOT, COLD OR CORROSIVE FLUID
PUMPING
DANGER
Extreme caution must be exercised by
trained and experienced operators
when flammable, hot, cold or corrosive
fluids are being pumped in order to
avoid personal injury, death and/or
equipment damage due to explosion,
fire, burn, extreme cold or chemical
attack.
Never operate a pump which is pumping
hydrocarbons or other flammable, hot, cold, or
corrosive fluids when any part of the pump, suction
system or discharge system is leaking. Stop the
pump immediately if any leakage, other than a few
drops per minute of packing weepage, is observed.
Keep all flame, sparks, or hot objects away from any
part of the pump, suction system, or discharge
system. Shield the pump, suction system and
discharge system to prevent any flammable, hot, cold