Gardner Denver PZG - 7", Operating And Service Manual

Page 1: ...GARDNER DENVER 15 600 Version 12 April 2002 TRIPLEX SINGLE ACTING PUMP MODELS PZG 7 PZH 8 PZJ 9 PZK 10 PZL 11 PXL 11 OPERATING AND SERVICE MANUAL ...

Page 2: ...g your pump Authorized distributor service technicians are factory trained and skilled 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 and OPI distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Gar...

Page 3: ...mical operation and minimum 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 Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate th...

Page 4: ...Oil Filter Mounting 10 Figure 6 Sizes and Ratings Models PZG and PZH 12 Figure 7 Sizes and Ratings Models PZJ and PZK 13 Figure 8 Sizes and Ratings Models PZL 14 Figure 9 Sizes and Ratings Models PZL High Pressure Fluid Cylinder 14 Figure 10 Sizes and Ratings Model PXL 15 Figure 11 Jackshaft Bearing Installation 16 Figure 12 Jackshaft Removal Installation Fixture 16 Figure 13 Oil Seal Wear Sleeve ...

Page 5: ...ef Valves 8 Surge Chamber 8 Starting A New Pump 8 Lubrication 9 Oil Filter 10 Heat Exchanger 10 Direction Of Rotation 10 Crosshead Drains 11 Operation 11 Maintenance Schedule 11 SECTION 3 16 Jackshaft 16 Lube Oil Pump 18 Connecting Rods 18 Eccentric And Gear AssemblyError Bookmark not defined Eccentric Cam Bearings 20 Assembly Of Eccentric And Gear Assembly In Frame 21 Main Bearings 21 Crosshead P...

Page 6: ...d instructions contained in these manuals If any of these documents are lost or become illegible they must be replaced immediately The danger notices plus the operating and service manuals should be reread periodically by both operators and maintenance personnel to refresh their memories in safe procedures and practices Keep in mind that full operator attention and alertness are required when oper...

Page 7: ...r lifted by trained experienced operators who are physically and mentally prepared to devote full attention and alertness to the moving and lifting operations An operator should be fully aware of the use capabilities and condition of both the equipment being moved and the equipment being used to move it DANGER Failure to follow safe and proper pump pump package or component lifting or moving proce...

Page 8: ...rge line and not at the opposite end of the discharge manifold in a dead end connection The dead end may become clogged with solid material carried in the fluid which could prevent proper relief valve operation DANGER Never place a shut off valve or any other component between the pump discharge connection and the pressure relief valve Make sure the pressure relief valve is installed so any pressu...

Page 9: ... 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 c...

Page 10: ...roof construction and all electrical components and wiring must meet the current National Electrical Code for explosive atmospheres These precautions must be taken to avoid possible personal injury death and or equipment damage from explosion fire or burns HIGH PRESSURE LIQUID JETTING BLASTING AND CLEANING DANGER Extreme caution must be exercised if any type of wand gun nozzle or any other pressur...

Page 11: ...ys 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 wa...

Page 12: ... working parts Check all joints in the suction line to be sure there are no air leaks DANGER When working on any pump be certain there is no fluid pressure on either the suction or discharge side Pressure on the fluid end might move the pump and cause damage or injury to personnel It is recommended that all suction valve covers be removed to avoid fluid pressure building up against the pistons or ...

Page 13: ...sure release valve should be furnished for each pump A hand operated pressure release valve should be installed in discharge line following the relief valve with discharge line leading to mud tank This valve is used to bleed air from discharge line in starting It is also used to relieve pressure in starting more than one pump in parallel SURGE CHAMBER A surge chamber is essential One MUST be used ...

Page 14: ...k 1000 Hours A P I Type GL 5 Lubricant Change oil and clean inside of frame Change oil filter element FIGURE 3 LUBRICATION SCHEDULE Failure to follow these lubrication requirements will void the warranty Some operating conditions and or oil brands produce excessive oil foaming even when the specified GL 5 oils containing antifoaming additives are used Oil foaming can cause pump damage as oil bubbl...

Page 15: ... changed or every 1000 hours of operation Filter element is protected from excessive internal oil pressure by a relief valve between it and the oil pump Filter element should be replaced each time crankcase oil is changed or every 1 000 hours of operation The filter element is protected from excessive internal oil pressure by a relief valve between it and the oil pump On units equipped with a heat...

Page 16: ...fluid is visible or becomes excessive 2 Clean inside frame cradle 3 Clean and refill piston wash tank after excessive contamination 4 Check piston wash baffle make certain nozzles are not clogged 5 Check pulsation dampener for proper charge Weekly 1 Remove valve covers and gaskets Replace if cut or warn 2 Check fluid valves and seats for wear Replace cut or worn inserts and valves 3 Inspect uretha...

Page 17: ...ump 17 410 lbs 7897 04 kg Gear Ratio 4 625 to 1 Length Over Skid 120 Inches 3048 0 mm Width Over Skid 50 Inches 1270 0 mm MODEL PZH 750 H P TRIPLEX MUD PUMP 3 7 177 8 8 203 2 4 0 15 14 580 2196 1996 140 3 76 817 34 844 145 652 750 3 6 1 2 165 1 8 203 2 3 45 13 06 500 1893 2315 162 8 76 817 34 844 145 652 750 3 6 158 8 8 203 2 3 19 12 08 462 1749 2504 176 0 76 817 34 844 145 652 750 3 6 152 4 8 203...

Page 18: ... 130 582 967 3 4 1 2 114 3 9 228 6 1 86 7 04 242 916 5000 315 5 79 522 36 071 130 582 783 3 4 101 6 9 228 6 1 46 5 53 191 723 5000 315 5 62 832 28 501 130 582 619 Weight Complete Pump 26 500 lbs 12 020 19 kg Gear Ratio 4 48 to 1 Length Over Skid 224 12 Inches 5692 648 mm Width Over Skid 96 Inches 2438 0 mm Width Over Jackshaft 80 20 Inches 2037 08 mm MODEL PZK 1 350 H P TRIPLEX MUD PUMP 3 7 177 8 ...

Page 19: ...0 500 lbs 18 370 48 kg Gear Ratio 4 38 to 1 Length Over Skid 222 5 Inches 5651 5 mm Width Over Skid 96 Inches 2438 4 mm Width Over Jackshaft 104 Inches 2641 6 mm MODEL PZL 1 600 H P TRIPLEX MUD PUMP HIGH PRESSURE 3 7 177 8 11 279 4 5 5 20 82 632 2392 3905 274 5 150 300 68 164 115 504 1600 3 6 1 2 165 1 11 279 4 4 74 17 94 545 2063 4529 318 4 150 300 68 164 115 504 1600 3 6 152 4 11 279 4 4 04 15 2...

Page 20: ...115 504 2000 3 6 1 2 165 1 11 279 4 4 74 17 94 545 2063 5662 298 0 187 875 85 219 115 504 2000 3 6 152 4 11 279 4 4 04 15 29 465 1760 6645 467 1 187 875 85 219 115 504 2000 3 5 1 2 139 7 11 279 4 3 40 12 83 390 1476 7500 527 2 178 125 80 797 115 504 1895 3 5 127 0 11 279 4 2 80 10 60 322 1219 7500 527 2 147 262 66 797 115 504 1565 Weight Complete Pump 46 250 lbs 20 978 63 kg Gear Ratio 4 38 to 1 L...

Page 21: ...herical main bearings Main bearings will be covered as a separate item The safest way to remove the inner race of the jackshaft bearing from the shaft is by the careful use of heat Do not overheat to the point where race is discolored Be careful not to damage the bearing spacer ring between the inner race and the shoulder on the shaft If the jackshaft bearing is to be replaced the outer race and r...

Page 22: ...permissible after gear or pinion teeth become badly worn Since gear is not on centerline of the frame it is necessary to move the oil pump and filter from original position to the opposite side of the frame and repipe as required Required direction of rotation of the pump provides that inner ends or apex of gear and pinion teeth lead This means that when viewing from the hood opening the inner end...

Page 23: ...he inlet and the right hand opening becomes the outlet When shaft rotation of the 201PAH188 oil pump changes direction the direction of flow changes without changing inlet and outlet port positions When reversing the complete gear sets on PZK PZL and PXL pumps the left hand helix pump drive gear must be replaced with an optional right hand helix drive gear Install the oil pump and drive gear assem...

Page 24: ...s over main bearings 4 Remove frame spacer blocks by removing them sideways as they are keyed to frame Be sure the 25 32 25 32 DRILL THRU ONE HOLE 29 32 DRILL THRU ONE HOLE 25 32 DRILL THRU ONE HOLE 7 8 DRILL THRU 2 HOLES 7 8 DRILL THRU 2 HOLES 1 2 DRILL THRU 2 HOLES 7 8 DRILL THRU 2 HOLES 1 5 3 0 4 5 1 75 69R 2 22 4 44 7 9R 45F 1 0 4 4 2 5 5 WELD 1 0 1 8 UNC THREAD FOR EYEBOLT DRILL THRU ONE HOLE...

Page 25: ...sassembly as well as during assembly 11 Eccentric and gear assembly with the connecting rod bearings on it can now be lifted and shifted to remove it from the frame Be sure to protect frame slot faces with a sheet material to prevent damage to them and to the tapered eccentric shaft THIS IS IMPORTANT It will be necessary to raise or lower and shift the suspended connecting rods to clear the eccent...

Page 26: ...n procedure covering removal of eccentric and gear assembly Be sure to support eccentric securely in its original location Remove lube oil pump gear to protect oil pump shaft as main gear might move during this operation Main bearing is a slip fit in the bearing cartridge or carrier and can be readily removed Remove inner retainer ring from end of cartridge if it is necessary to drive the bearing ...

Page 27: ...15 600 Page 22 FIGURE 18 FIGURE 19 FIGURE 20 FIGURE 21 ...

Page 28: ...15 600 Page 23 FIGURE 22 FIGURE 23 FIGURE 24 FIGURE 25 ...

Page 29: ... the drive pinion on the shaft of the lube oil pump 21 Remove all tools and loose parts from the crankcase Remove the device use to support the weight of the eccentric assembly 22 Replace lube oil pump Put the hood back in place Be sure the gasket is in good condition and in proper location Bolt down securely Use grease on frame flange to help keep hood gasket in place 23 Do not forget to replace ...

Page 30: ...re not adjustable The inner seal lip is pointed inward toward the crankcase to strip oil from the push rod The outer seal lip points outward toward liner to strip mud and or water from the push rod Be certain seals are properly installed The seal adaptors with seals in them can be slipped off and on the push rods by removing the clamp holding piston rods against the push rods and separating the tw...

Page 31: ...They are provided with a knurled section so rod can be held while tightening piston nut It is important that piston rod nut be tightened to recommended torque shown on pages 31 and 32 Piston rod to piston fit is straight Piston fits against flange on piston rod with on O ring gasket to prevent l connecting flanges and pilots DO NOT use a screwdriver or cold chisel to separate the flanges turn the ...

Page 32: ...cause rapid wear of valve guides and should be replaced It will also cause wear on suction valve guide mounting lugs inside the valve chamber cylinder Do not put a used valve assembly on a new seat unless it is in practically a new condition Be sure to replace a doubtful insert to protect seat and bumper It requires experience and judgment to determine if valve parts should be replaced or not Valv...

Page 33: ...oose Tight Loose Tight Loose Jackshaft Bearing on Shaft 0017 0037 0432 0940 0020 0043 0508 1092 Tight Tight Tight Tight Tight Tight Tight Tight Connecting Rod to Eccentric Bearing OD in Connecting Rod 004 000 102 000 0034 0000 0889 0000 Tight Tight Tight Tight ID on Eccentric 0072 0110 1829 2794 0080 0115 2032 2921 Tight Tight Tight Tight Tight Tight Tight Tight Crosshead Pin Bearing OD in Connect...

Page 34: ...se Tight Loose Jackshaft Bearing on Shaft 0020 0043 0508 1092 0020 0044 0508 1118 Tight Tight Tight Tight Tight Tight Tight Tight Connecting Rod to Eccentric Bearing OD in Connecting Rod 004 000 102 000 004 000 102 000 Tight Tight Tight Tight ID on Eccentric 009 013 229 330 011 015 2794 381 Tight Tight Tight Tight Tight Tight Tight Tight Crosshead Pin Bearing OD in Connecting Rod 0027 0000 0686 00...

Page 35: ... Jackshaft Bearing OD in Housing 0014 0025 0356 0635 Tight Loose Tight Loose Jackshaft Bearing on Shaft 0020 0044 0508 1118 Tight Tight Tight Tight Connecting Rod to Eccentric Bearing OD in Connecting Rod 004 000 102 000 Tight Tight ID on Eccentric 0110 0150 2794 381 Tight Tight Tight Tight Crosshead Pin Bearing OD in Connecting Rod 0018 0040 0457 1016 Tight Tight ID in Crosshead Pin 0010 0032 025...

Page 36: ...ame Stud Nut PZG PZH PZJ 1 1 4 Studs 750 Ft Lbs 103 7 kg m PZK PZL LP 1 1 4 Studs 750 Ft Lbs 103 7 kg m PZK PZL HP 1 1 4 Studs 1400 Ft Lbs 193 kg m Piston Rod to Extension Rod Threaded Style 1000 Ft Lbs 138 26 kg m 2 Piece PZK PZL HP Piston Rod Stud Coupling Style 1000 Ft Lbs 138 26 kg m Piston Rod to Extension Rod Coupling Screw or Nut Coupling Style 75 Ft Lbs 10 37 kg m Crosshead Pin Retaining P...

Page 37: ... Lbs 221 22kg m Liner Clamp to Frame Stud Nut 1 1 4 Studs 1400 Ft Lbs 193 kg m 2 Piece HP Piston Rod Stud Coupling Style 1000 Ft Lbs 138 26 kg m Piston Rod to Extension Rod Coupling Screw or Nut Coupling Style 75 Ft Lbs 10 37 kg m Crosshead Pin Retaining Plate Screw 370 Ft Lbs 51 17kg m Crosshead Extension to Crosshead Screw 220 Ft Lbs 30 43 kg m Valve Cover Lock Ring to Cylinder Screw 1 1 4 Studs...

Page 38: ...workmanship for 6 months from the date of installation or 18 months from the date of delivery to the purchaser which ever occurs first 3 Repairs are warranted for 90 days from the date of delivery for the workmanship and materials of the new parts installed 4 Weld repaired fluid ends and weld repaired components are not warranted 5 Expendable fluid end parts including but not limited to valves val...

Page 39: ...EREUNDER WHICH ARE NOT MANUFACTURED BY COMPANY NOTWITHSTANDING ANYTHING HEREIN TO THE CONTRARY THE FOREGOING WARRANTY SHALL BE THE SOLE AND EXCLUSIVE REMEDY AVAILABLE TO THE PURCHASER UNDER NO CIRCUMSTANCES WHETHER IN CONTRACT TORT OR OTHERWISE SHALL THE COMPANY S TOTAL LIABILITY ARISING IN CONNECTION WITH ANY PURCHASE ORDER EXCEED THE AMOUNT OF ANY SALES OR OTHER PROCEEDS RECEIVED PURSUANT THERET...

Page 40: ...1 Customer Service Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946 FAX 901 542 6159 Specifications subject to change without notice Copyright 1999 Gardner Denver Inc Litho in U S A http www gardnerdenver com ...