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High  pressure  fluid  from  hand  held  or  hand 
directed pressure and flow directing devices 
may  overpower  an  operator’s  ability  to 
control  or  direct  the  device,  which  could 
lead  to  personal  injury,  death  and/or 
equipment  damage.    The  operator  must 
brace against the backward thrust of a hand 
held device.  In addition, a safety harness or 
safety net must be used when working in an 
area  where  the  operator  could  be  injured  in 
a  fall.    Stand  to  the  side  of  any  tubing  or 
container being sprayed to avoid back spray 
and  never  operate  a  hand  held  device 
above shoulder level.  
 
Never  direct  the  pressurized  fluid  stream at 
yourself or any other person, control valves, 
the  pump, pump drive, suction or discharge 
systems.    The  pressurized  stream  can 
cause  serious  personal  injury  or  death  and 
can  also  change  valve  or  control  settings 
which  could  dangerously  increase  the 
delivery  pressure  to  the  pressure  and  flow 
directing device. 
 
When  operating  a  pressure  and  flow 
directing  device,  use  only  equipment  which 
automatically  shuts  off  flow  when  an 
operator  releases  hand  or  foot  pressure  on 
the  pressurized  flow  trigger  control  to 
prevent injury if the operator is overpowered 
or becomes disabled. 
 
Check  to  insure  this  automatic  shut-off 
equipment  is  operating  properly  before 
every  use  and  never  circumvent  the 
automatic  shut-off  for  any  reason  or by any 
means when operating the equipment. 
 
When  operating  any  type  of  high  pressure 
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  nonskid  sole  and 
safety  toe,  rubber  gloves  with  rough  grip 
surface and ear noise protection. 
 
Full  operator  attention  and  alertness  are 
required  when  operating  this  equipment  to 
avoid 

personal 

injury, 

death 

and/or 

equipment  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  to  avoid  personal  injury,  death, 
and/or  damage  to  equipment.    Make  sure 
the  work  area  is  checked  for  hazardous 
fumes,  has  adequate  ventilation  for  engine 
exhaust and sufficient drainage for released 
fluid.    Check  the  work  area  for  electrical 
equipment,  connections,  outlets, fixtures, or 
lines.  If any are present they must be made 
water tight and the electrical power to these 
devices  must  be  shut  off  to  avoid  electrical 
shocks  from  fluid  contact.    The  work  area 
should  be  clearly  marked  and  roped  off  to 
keep unauthorized people and vehicles from 
entering.  Remove all loose parts, tools and 
equipment  from  the  work  area  before 
beginning operation. 
 
All  pressure  containing  devices  including 
wands,  nozzles,  guns,  hoses,  connections, 
etc.,  should  be  regularly  checked  for 
condition.    These components should all be 
tagged with their tested pressure capabilities 
together 

with 

the 

date 

testing 

was 

performed.    Always  be  aware  of  the 
pressure  level  in  the  system  and  never 
connect  any  equipment  to  the  system 
which  has  a  rated  or  tested  pressure 
capability  below  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  shut-off,  pressure  and 
control  equipment  should  be  treated  with 
care.  Protect them from damage by people, 
objects  and  vehicles.    Never  lay  them  in 
dirt,  mud,  ice  or  other  loose  material  which 
could plug the fluid opening or interfere with 
their  operation.    Never  use  the  wand, 
nozzle,  gun,  etc.  to  pry  loose  material  off 
items being cleaned. 
 
Before 

starting 

operation 

in 

cold 

environment,  check  to  make  sure  there  is 
no  ice  in  the  fluid  system  and  repeat  this 
inspection  each  time  before  operation  is 
restarted.

Содержание GD-3000

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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