Gardner Denver C2500Q QUINTUPLEX Operating And Service Manual
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Gardner Denver C2500Q QUINTUPLEX Operating And Service Manual

Gardner Denver C2500Q QUINTUPLEX Operating And Service Manual

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GARDNER DENVER
®
300CMC996 Revision C
April 2011
WELL SERVICING PUMP
MODEL
C2500Q QUINTUPLEX
OPERATING AND
SERVICE MANUAL
ECN 1058968

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Summary of Contents for Gardner Denver C2500Q QUINTUPLEX

  • Page 1 GARDNER DENVER ® 300CMC996 Revision C April 2011 WELL SERVICING PUMP MODEL C2500Q QUINTUPLEX OPERATING AND SERVICE MANUAL ECN 1058968...

  • Page 2: Instructions For Ordering Repair Parts

    Reliability in materials and quality assurance is incorporated in our genuine replacement parts. Your authorized Gardner Denver Sales Office offers all the backup you’ll need. The Fort Worth and Tulsa Manufacturing Facilities maintain a large inventory of genuine parts.

  • Page 3: Foreword

    FOREWORD Gardner Denver® pumps are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this pump the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance personnel essential information for day-to-day operation, maintenance and adjustment.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and Support Services ......................i Instructions For Ordering Repair Parts .................. i Foreword..........................ii Index............................. iv List of Illustrations ......................... v Section 1, Danger Notices..................... 1 Section 2, Design and Description..................9 Section 3, Preparation, Operation and Maintenance..............

  • Page 5: Index

    INDEX Crankshaft Assembly........25 Crankshaft Replacement ......26 Periodic Routine Maintenance Schedule..17 Crosshead Assembly …......23 Plunger / Packing Lubrication ......16 Crosshead Guide and Stay Rods ….... 24 Plunger Packing Lubrication Recommendation Chart ............19 Daily Routine Maintenance Schedule..18 Plungers and Packing Replacement ....

  • Page 6: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure Description Page Figure 2-1 C-2500Q Quintuplex Pump..............9 Figure 2-2 C-2500Q Gear Reduction Unit ............... 11 Figure 2-3 C-2500Q Fluid End ................13 Figure 3-1 Lubricant Recommendations ..............16 Figure 4-1 Fluid End Removal and Assembly ............21 Figure 4-2 Packing Assembly .................

  • Page 7: Section 1, Danger Notices

    Replace any of these parts which are application of the pump outside the limits, cracked, damaged or badly worn. must not be made without Gardner Denver written approval, together with a new set of Wear safety shoes and safety glasses.

  • Page 8: Covers And Guards

    Wipe their hands and the hammer • handle and maintain a firm grip on the Fully engage the wedge to prevent it • handle to avoid losing control of the from disengaging violently from the hammer while swinging and striking. cover as a blow is struck.

  • Page 9: Pressurized Pump Systems

    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 lifting devices DANGER should be fastened to the lifting attachments normally built into the individual motor, engine, pump or transmission / torque Failure to follow safe and proper converter, or their separate support skids.
  • Page 10 Before starting the pump every time, check to insure: Operating a pump against a blocked or The pressure relief valve is in good restricted discharge line produce • excessive pressures in the entire discharge operating condition and has been set to system, which damage...

  • Page 11: Flammable, Hot, Cold Or Corrosive Fluid Pumping

    Proper stuffing box packing selection is Due to the high working pressures contained important for safe pump operation. Contact by the fluid end, discharge manifold and a Gardner Denver service representative for discharge piping, welding these assistance in selecting the proper packing components is not recommended.

  • Page 12: High Pressure Liquid Jetting

    units where flammable or explosive vapors equipment damage due to explosion, could form should be equipped with an air fire, extreme cold or chemical attack. inlet shut-off. If flammable or explosive vapors are present in the pumping site Never operate a pump that is pumping atmosphere, an engine could continue to hydrocarbons or other flammable, hot, cold, run on these vapors even after the engine...
  • Page 13 vehicles. A broken, cut or otherwise burst Full operator attention and alertness are hose can release pressurized fluid that may required when operating this equipment to cause personal injury, death and/or avoid personal injury, death and/or equipment damage. equipment damage. The operators should take frequent rest breaks and cease...
  • Page 14 nozzle, gun, etc. to pry loose material off items being cleaned. Before starting operation cold environment, check to make sure there is no ice in the fluid system and repeat this inspection each time before operation is restarted. Before purchasing wands, nozzles, guns, connections, hoses, etc., manufacturers of these components should be contacted for detailed information on the design and...

  • Page 15: Design Description And Specifications, Section 2

    SECTION 2 DESIGN, DESCRIPTION AND SPECIFICATIONS The sections on Pump Design, Description, INTRODUCTION and Specifications, describe the pump design, list the pump specifications, and The Gardner Denver C2500 is a high horsepower, high rod load multi-purpose present drawings depicting pump...

  • Page 16: Pump Design

    Section 4, "Service Procedures," describes The crossheads and crosshead-guides are various assembly disassembly full-cylindrical design for minimum PV procedures. loading maximum lubricity. connecting rods bolt to the conn-rod bearing Section 5, “Trouble–Shooting,” describes housings. The conn-rod bearing housings possible problems, causes and solutions are accessible through the rear of the pump, related to pump performance.

  • Page 17: Figure 2-2 C-2500Q Gear Reduction Unit

    end sump. Oil is also drained from the gear POWER END AND GEAR REDUCTION covers through drain holes in the outside UNIT LUBE SYSTEM (FIGURE 2-1 and frame plates. These drains are all combined FIGURE 2-2) together and empty into the main drains in the bottom of the pump frame.

  • Page 18: Figure 2-3 C-2500Q Fluid End

    FLUID END (FIGURE 2-3) The EWS Fluid End is a forged alloy steel block is designed for severe applications. The EWS utilizes heat-treated “Ultima 1” This fluid end incorporates the traditional Stem Guided Valves to provide increased flange-mounted fluid end design, which simplifies installation and removal by simply valve life and improved fluid pass through to reduce cavitation.
  • Page 19 GENERAL SPECIFICATIONS This section presents the pump basic specifications. The first set of specifications deals with the pump's power, rod load, plunger stroke, and overall dimensions. The other table presents allowable pressures and flows for various pump speeds along with data on power requirements. C2500Q PERFORMANCE RATING Rated Brake Horsepower 2500BHP...

  • Page 20: Section 3, Preparation, Operation And Maintenance

    SECTION 3 PREPARATION, OPERATION AND MAINTENANCE DANGER Coat the gear reducer input shaft and all bear metal with a heavy rust preventive. Read and understand clearly all safety rules and precautions before Plug drain holes at the bottom of the attempting to operate the pump.

  • Page 21: Lube Pump Suction Piping Sizing And Requirements

    guidelines, developed as a result of long Bolt brackets to pump, using 7/8” – experience, should be adhered to closely. 9UNC Grade 8 bolts. The oil flow velocity through the suc- When connecting the suction line to tion piping should not exceed 2 ft/sec. the suction manifold, provide support to the suction line independent of the At maximum operating speed the...

  • Page 22: Startup And New Pump Run-In Procedure

    FIGURE 3-1 indicates API-GL5 oil grades operating temperature ranges and minimum recommended for use in the pump power end startup temperatures for each listed grade of oil and the gear reducer lube system. Crankcase for various inlet or sump temperature ranges. FIGURE 3-1: Lubricant Recommendations quintuplex pump so that there is no less PLUNGER / PACKING LUBRICATION...

  • Page 23: Periodic Routine Maintenance Schedule

    12. Run the pump at 80-90 strokes per min assist the user, the following guidelines are presented for the maintenance personnel to at the following loads: 40% of full rated load 30 min follow during the critical startup and break-in 60% of full rated load 30 min period:...
  • Page 24 trouble free operation of this pump. It is Monthly (100 hour) Routine Maintenance highly recommended that the customer set Tasks up a maintenance program during the run-in Clean the strainer and replace the oil period. The periodic maintenance data filter element. should be recorded and kept with other Check the entire lube system for leaks pump...

  • Page 25: Plunger / Packing Lubrication

    PLUNGER PACKING LUBRICATION RECOMMENDATION CHART ROCK DRILL LUBRICANTS - NORMAL CONDITIONS Source Type Pour Point Maximum Amoco Amoco Rock Drill Oil - Light -20°F Amoco Rock Drill Oil - Medium 0°F Arco Air Drill #147 0°F Arco Trueslide #150 15°F Chevron Oil U.S.A.

  • Page 26: Section 4, Service Procedures

    SECTION 4 SERVICE PROCEDURES This section describes various assembly working on pump. and disassembly procedures necessary for FLUID END SERVICE pump servicing or parts replacement. The General Requirements and Safety Rules This discussion starts with the description of section is a reminder for the maintenance steps necessary for removal and installation personnel of the critical importance of safety of the fluid cylinder assembly and proceeds...

  • Page 27: Plungers And Packing Replacement

    FIGURE 4-1 C-2500 Fluid End NOTICE Plunger and Packing Replacement While the stay-rod are available to inspection, check loose stay-rods This service procedure can be performed and cracked threads in all stay-rods. with the fluid cylinder in place on the pump, The connection between the power and consists of the following steps: end and the fluid end is a critical one.

  • Page 28: Plunger Size Change

    WARNING and a seat puller jack. These tools are available from Gardner Denver. (See “Special Tools” section of Parts List.) Never try to remove or cut a valve seat with a torch. Severe damage to 11.

  • Page 29: Power End

    safety precautions must 12. Be sure the O-ring is installed on the observed: seat and snap the valve seat into the Shift the pump transmission into taper by hand to fit tightly. the neutral gear. Shut off the pump engine and 13.

  • Page 30: Crosshead Guide And Stay Rods

    If the crosshead guides must be the crosshead. replaced, it is recommended that it be done either by Gardner Denver or a 10. To remove the pivot head from the two qualified machine shop. piece conn-rod cut the tie wire and remove the four ¾”-16 Flange Bolts.

  • Page 31: Crankshaft Assembly

    Gear Reduction Unit Remove the fluid end as described in "Fluid End Removal and Installation," NOTICE page 20. This assembly is a timed gear set, Remove the oil stop head seal retainer and should be changed as a gear set. and gear covers as described in “Oil If one gear is changed, both should Stop Head Seal Retainer and Gear...
  • Page 32 Page 26...

  • Page 33: Crankshaft Replacement

    Crankshaft Replacement 1. Determine which is no. 1 throw. Place crankshaft in a vertical position, either WARNING in special fixture or a bull-gear lying flat on the ground, with the no. 1 throw When reassembling crankshaft down toward or nearest the ground. assembly, make sure to follow these steps: 2.

  • Page 34: Section 5, Trouble-Shooting

    SECTION 5 TROUBLE-SHOOTING PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Pump Overloads Driver. 1. Excessive pump speed 1. Reduce pump speed and/or and/or discharge pressure. pressure. 2. Blockage or closed 2. Clean or open valve. valve in discharge line. 3. Incorrect plunger size. 3.
  • Page 35 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Cavitation, Fluid Knock 1. Improper suction system 1. See recommended system or Hammer. layout. layout in manual. 2. Low suction pressure. 2. See Low Suction Pressure problem. 3. Suction stabilizer and 3. Install suction stabilizer pulsation damper not used.
  • Page 36 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Knock In Power End. 1. Improper main bearing 1. Check and adjust clearance. clearances. 2. Incorrect pump rotation. 2. Reverse rotation. 3. Loose plunger coupling. 3. Check and tighten. Replace if damaged. 4. Loose bearing housings/ 4.
  • Page 37 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Oil Seal Leakage. 1. Worn sealing lip. 1. Replace seal. 2. Damaged sealing lip. 2. Replace seal. 3. Outside diameter not seated. 3. Clean and polish bore of oil seal housing. 4. Shaft rough at seal lip. 4.
  • Page 38 PROBLEM POSSIBLE CAUSE SUGGESTED ACTION Short Plunger/Packing Life. 1. Abrasives in pumped fluid. 1. Consult Gardner Denver Customer Service for plunger packing recommendation. Filter pumped fluid. 2. Excessive plunger/packing 2. Lubricate with rock drill oil. friction. Do not overtighten adjust- able packing.
  • Page 39 4. Corrosive attack by pumped 4. Treat fluid or use corrosion fluid. resistant studs. 5. Studs damaged before 5. Check condition before installation. installation, and replace if necessary. 6. Low strength studs. 6. Use Gardner Denver studs. Page 33...

  • Page 40: Section 6, Rebuilding Data, Recommended Running Clearances And Torques

    SECTION 6 REBUILDING DATA, RECOMMENDED RUNNING CLEARANCES AND TORQUES REBUILDING DATA FOR C-2500 PUMP (in.) PUMP STROKE 8 Inches Crankshaft Throw Diameter..........7.251” / 7.249” Crankshaft Shaft Diameter at Main Bearing ...... 16.002” / 16.001” Distance Between Main Bearing Centers......12.00” Bore in Frame for Main Bearings........
  • Page 41 Page 34...
  • Page 42 RECOMMENDED TORQUES FOR C-2500Q PUMP MAINTENANCE TORQUES FOOT POUNDS DESCRIPTION FASTENER WITH LOCTITE WITH ANTISEIZE Gear Covers, Misc..........3/8”-16 Main Bearing retainer plate screws (Gr. 8)………1/2”-13 ................5/8”-11 Plunger Clamp Bolts………………………………..1/2”-13 ................5/8”-11 Pinion Bearing Housing........3/4”-10 Intermediate Rod to Crosshead ......3/4”-10 Conn Rod to Bearing Housing, Lock Nuts………..3/4”-10 Fluid End Suction Manifold ........7/8”- 9 Discharge Flange to Fluid Cylinder Nuts.....

  • Page 43: Warranty

    BE-13 R 02/2003, Copyright © 2003 Gardner Denver, Inc. GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the "Company") warrants to each original retail purchaser ("Purchaser") of its new products, assemblies or parts from the Company or its authorized distributors that such products are, at the time of delivery to the Purchaser, made with good material and workmanship.
  • Page 44 Rotate pump every 30 days to insure bearings are oiled. At the expense of the Purchaser, any product properly preserved must be inspected by an authorized agent of the Company, prior to the Company, granting any extended warranty beyond that stated in this warranty. LABOR TRANSPORTATION AND INSPECTION The Company will provide labor, by Company representative or authorized service personnel, for repair or replacement of any product or part thereof which in the Company's judgment is proved not to...
  • Page 45 Company prior to shipment. All requests for product return shall be submitted by email. Facsimile or letter to: Warranty Department c/o Gardner Denver Petroleum Pumps 4747 South 83 East Avenue Tulsa, Oklahoma 74145 Email: CCR.QAR@gardnerdenver.com Facsimile: (918) 664-6225 BE-13 R 02/2003, Copyright © 2003 Gardner Denver, Inc. Page 38...
  • Page 46 For additional information contact your local representative or Gardner Denver Inc. 4747 South 83 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. Copyright © 2001 Gardner Denver, Inc. Litho in U.S.A.

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