Gardner Denver PZG – 7” Operating And Service Manual
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Gardner Denver PZG – 7” Operating And Service Manual

7/8/9/10/11" triplex single acting pump
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15-600
GARDNER DENVER
®
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

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  • Page 1 15-600 GARDNER DENVER ® 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: Instructions For Ordering Repair Parts

    MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH GENUINE GARDNER DENVER PARTS AND SUPPORT SERVICES Gardner Denver and OPI genuine pump parts are manufactured to design tolerances and developed for optimum dependability. Design and material innovations are the result of years of experience with hundreds of different pump applications.

  • Page 3: Foreword

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

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Maintain Pump Reliability and Performance ......................i Instructions For Ordering Repair Parts........................i Foreword................................ii Index ..................................iv SECTION 1, Danger Notices..........................1 SECTION 2, Installation & Operating Instructions....................7 SECTION 3, Routine Maintenance & Service Instructions................. 16 SECTION 4, Dimensions & Running Clearances....................28 LIST OF ILLUSTRATIONS Figure 1 Final Shimming ..........................

  • Page 5: Index

    INDEX Maintenance Schedule..........11 Maintain Pump Reliability And Performance ....i Ordering Repair Parts..........i SECTION 3...............16 Foreword..............ii Jackshaft ..............16 Lube Oil Pump............18 SECTION 1..............1 Hammer Lug Fasteners..........1 Connecting Rods ............18 Valve Seat Pulling............2 Eccentric And Gear AssemblyError! Bookmark not defined.

  • Page 6: Section 1, Danger Notices

    SECTION 1 DANGER NOTICES operators and maintenance personnel to refresh their DANGER memories in safe procedures and practices. Read understand following DANGER Keep in mind that full operator attention and alertness NOTICES before moving or operating the pump or any are required when operating high pressure pumping pump package unit equipment.

  • Page 7: Valve Seat Pulling

    • Carefully swing the hammer to avoid striking EQUIPMENT MOVING AND LIFTING themselves, another person and objects other DANGER than the targeted lugs or hammer bar. • Avoid swinging the hammer above shoulder Heavy equipment including pumps, pump package height. units and components should only be moved or lifted by trained, experienced operators, who are physically VALVE SEAT PULLING...

  • Page 8: Pressurized Pump Systems

    loads. For these smaller loads the lifting devices The relief valve should be placed in the flowing should be fastened to the lifting attachments normally discharge line and not at the opposite end of the built into the individual motor, engine, pump or discharge manifold in a dead end connection.

  • Page 9: Flammable, Hot, Cold Or Corrosive Fluidpumping

    Worn or damaged hose assemblies should be Whenever the pump is operating, continually monitor replaced immediately. At least every six months the entire suction, discharge and pump lubricating examine hose assemblies internally for cut or bulged systems for leaks. Thoroughly investigate the cause tube, obstructions and cleanliness.

  • Page 10: High Pressure Liquid Jetting, Blasting And Cleaning

    or corrosive fluid leakage from dripping or spraying on HIGH PRESSURE LIQUID JETTING, BLASTING any components, flame, sparks, hot objects or people. AND CLEANING Inspect the plungers, packing, gaskets and seals for fluid leakage frequently and replace all worn or leaking DANGER parts.
  • Page 11 Check to insure this automatic shut-off equipment is The equipment must be shut down and the system operating properly before every use and never pressure released before changing or disconnecting circumvent the automatic shut-off for any reason or by wands, nozzles, guns, hoses, connections or any any means when operating the equipment.

  • Page 12: Section 2, Installation & Operating Instructions

    SECTION 2 INSTALLATION & OPERATING INSTRUCTIONS FOR GARDNER DENVER PZ SERIES & PXL SINGLE ACTING POWER PUMPS Reference to Parts List covering the Model Pump being serviced is recommended in connection with this Instruction Manual. Repair Parts Lists with Sectional Views are available from any Gardner Denver Sales and Service Office.

  • Page 13: Figure 1 Final Shimming

    DANGER Never install a shutoff valve in the line NOTE: between the pressure relief valve and This is only when the skid is secured to a STATIONARY foundation. the pump discharge manifold. DIAL FRAME SUPPORT INDICATOR FOOT If more than one pump is used, a pressure release valve should be furnished for each pump.

  • Page 14: Figure 2 Crankcase Oil Requirements

    FIGURE 2 – CRANKCASE OIL REQUIREMENTS LUBRICATION - All power end working parts are • Failure to follow these lubrication requirements will lubricated by the oil in the crankcase. Check oil level void the warranty. frequently. Selection of oil is to be taken from the •...

  • Page 15: Figure 4 Oil Capacities

    On units equipped with a heat exchanger, oil flows through the oil filter before going through the heat OIL CAPACITIES exchanger. Pumps Without Heat Exchanger Model Cast Frame Fabricated Frame 60 Gal. (227.1 Liters) None 60 Gal. (227.1 Liters) 85 Gal. (321.8 Liters) 70 Gal.

  • Page 16: Crosshead Drains

    Running the pump in the prescribed direction insures It is recommended that these openings be piped proper lubrication and quiet operation as the load on together and a valve installed to simplify the daily the crosshead will be carried on the lower side. draining.

  • Page 17: Figure 6 Sizes And Ratings - Models Pzg And Pzh

    Cylinder Displacement Maximum Jack- Qty. Diameter Stroke Pressure Piston Load Gal. Per Liter Per Gal. Per Liter Per Pump shaft Input Inches Inches Rev. Rev. Min. Min. kg/cm2 Pounds MODEL PZG – 550 H.P. TRIPLEX MUD PUMP 177.8 177.8 13.25 1919 1673 117.6...

  • Page 18: Figure 7 Sizes And Ratings - Models Pzj And Pzk

    Cylinder Displacement Maximum Jack- Qty. Diameter Stroke Pressure Piston Load Gal. Per Liter Per Gal. Per Liter Per Pump shaft Input Inches Inches Rev. Rev. Min. Min. kg/cm2 Pounds MODEL PZJ – 1,000 H.P. TRIPLEX MUD PUMP 177.8 228.6 17.03 2215 2639 185.5...

  • Page 19: Figure 8 Sizes And Ratings - Models Pzl

    Cylinder Displacement Maximum Jack- Qty. Diameter Stroke Pressure Piston Load Gal. Per Liter Per Gal. Per Liter Per Pump shaft Input Inches Inches Rev. Rev. Min. Min. kg/cm2 Pounds MODEL PZL – 1,600 H.P. TRIPLEX MUD PUMP 177.8 279.4 5.50 20.82 2392 3905...

  • Page 20: Figure 10 Sizes And Ratings - Model Pxl

    Cylinder Displacement Maximum Jack- Qty. Diameter Stroke Pressure Piston Load Gal. Per Liter Per Gal. Per Liter Per Pump shaft Input Inches Inches Rev. Rev. Min. Min. kg/cm2 Pounds MODEL PXL – 2,000 H.P. TRIPLEX MUD PUMP 177.8 279.4 5.50 20.82 2392 4882...

  • Page 21: Section 3, Routine Maintenance & Service Instructions

    SECTION 3 ROUTINE MAINTENANCE & SERVICE INSTRUCTIONS spacer ring between the inner race and the shoulder Remove hood and crosshead inspection plates for on the shaft. access to working parts. Before working on inside of If the jackshaft bearing is to be replaced, the outer crankcase, it is necessary to drain the oil.

  • Page 22: Figure 13 Oil Seal Wear Sleeve Installation Tool

    Stroke: Stroke: Stroke: Stroke: Stroke: Stroke: 7” 8” 9” 10” 11” 11” Dimensions Inches Inches Inches Inches Inches Inches 14.0 16.0 12.0 12.0 10.0 B Diameter 7.75 197.0 8.335 211.71 10.75 273.0 10.75 273.0 11.5 292.1 13.0 13.0 1.75 44.5 1.75 44.5 1.00...

  • Page 23: Figure 14 Connecting Rod Support

    level oil trough properly. Top of oil trough is to be level. The PZG pump does not have oil trough. Outer oil seals are to be placed in the bearing end plate after it is bolted to the bearing housing and frame.

  • Page 24: Figure 15 Eccentric And Gear Assembly Support

    ECCENTRIC AND GEAR ASSEMBLY - WARNING Be sure to remove the oil pump drive pinion when removing or replacing the eccentric and gear asembly to avoid bending the oil pump shaft when the gear is removed. Eccentric and shaft are made in one piece. Eccentric and gear assembly is to be removed from the frame for the following reasons: (a) Assembly is to be reversed after gear is worn.

  • Page 25: Figure 17 Table Of Metric Equivalents For Dimensions (Inches)

    METRIC EQUIVALENTS Inches Inches 3/8 (.375)................ 9.525 3................. 76.2 .38 .................. 9.652 3.20................81.28 .68 .................. 17.272 4.0................101.6 .69 .................. 17.526 4.2................106.68 25/32 (.78125)..............19.844 4.44................112.776 7/8 (.875)................ 22.225 4.5................114.3 .88 .................. 22.352 4.56................115.824 29/32 (.90625)..............23.019 4.88................

  • Page 26: Assembly Of Eccentric And Gear Assembly In Frame

    between inner race and rollers. See 28 thru 30 for Main bearing is a slip fit in the bearing cartridge or recommended running clearances. carrier, and can be readily removed. Remove inner retainer ring from end of cartridge if it is necessary to Inner races are equipped with an end ring.
  • Page 27 FIGURE 18 FIGURE 19 FIGURE 20 FIGURE 21 15-600 Page 22...
  • Page 28 FIGURE 22 FIGURE 23 FIGURE 24 FIGURE 25 15-600 Page 23...

  • Page 29: Crosshead Pins

    13. Mount shim pack on end of journal and assemble 22. Replace lube oil pump. Put the hood back in bearing retainer plate. place. Be sure the gasket is in good condition and in proper location. Bolt down securely. Use grease 14.

  • Page 30: Figure 26 Installation Of Push Rods

    in frame, or through crosshead inspection openings. OIL STOP HEADS - Oil stop heads keep the crankcase oil within the frame. They also keep mud and liner washing fluids from entering the crankcase. Oil stop packing consists of two identical seals mounted in adaptors.

  • Page 31: Liner Clamp And Liners

    compound gasket seals end of liner against valve section so rod can be held while tightening piston nut. chamber. When replacing a valve chamber it is It is important that piston rod nut be tightened to necessary to remove the discharge manifold. Also recommended torque shown on pages 31 and 32.

  • Page 32: Suction Strainer

    When removing a worn valve seat, use the Gardner- Do not put a used valve assembly on a new seat Denver puller powered with a hydraulic jack. Be careful unless it is in practically a new condition. Be sure to to chain or tie the jack down as it will jump violently replace a doubtful insert to protect seat and bumper.

  • Page 33: Section 4, Dimensions & Running Clearances

    SECTION 4 DIMENSIONS & RUNNING CLEARANCES RECOMMENDED RUNNING CLEARANCES Inches Inches (AFTER ASSEMBLY) Crosshead to slide .020 .037 .508 .940 .020 .037 .508 .940 Main Bearing .001 .004 .025 .102 .003 .006 .076 .152 Jackshaft Bearing .001 .006 .025 .152 .002 .006 .051...
  • Page 34 RECOMMENDED RUNNING CLEARANCES Inches Inches (AFTER ASSEMBLY) Crosshead to slide .020 .037 .508 .940 .025 .042 .635 1.067 Main Bearing .005 .008 .127 .203 .003 .008 .076 .203 Jackshaft Bearing .002 .004 .051 .102 .002 .008 .051 .203 Crosshead Pin Bearing .002 .005 .025...
  • Page 35 RECOMMENDED RUNNING CLEARANCES Inches (AFTER ASSEMBLY) Crosshead to slide .025 .042 .635 1.067 Main Bearing .003 .008 .076 .203 Jackshaft Bearing .002 .008 .051 .203 Crosshead Pin Bearing .000 .006 .000 .152 Connecting Rod to Eccentric Bearing .000 .010 .000 .254 Oil Pump Pinion to Main Gear –...
  • Page 36 RECOMMENDED TORQUES – "PZ MODELS" (DRY) Cylinder To Frame Stud Nut: PZG, PZH & PZJ (1-1/4” Studs) 1800 Ft.Lbs. (248.87 kg-m) PZG, PZH & PZJ (7/8” Studs) 600 Ft. Lbs. (82.98 kg-m) PZK & PZL (1-1/4” Studs) 1800 Ft. Lbs. (248.87 kg-m) Discharge Manifold Stud Nut: PZG, PZH &...
  • Page 37 RECOMMENDED TORQUES -"PXL " (DRY) CylinderTo Frame Stud Nut (1-1/4" Studs) ................1800 Ft.Lbs. (248.87 kg-m) Discharge Manifold Stud Nut (1-1/4" Studs) .................1150 Ft. Lbs. (159.0 kg-m) ConnectingRodBolt ........................700 Ft.Lbs.(96.78kg-m) Piston Rod Nut..........................1100 Ft. Lbs. (152.09 kg-m) Frame Spacer Clamp Studs ......................1600 Ft.Lbs.(221.22kg-m) Liner Clamp to Frame Stud Nut (1-1/4"...

  • Page 38: Product Warranty

    PRODUCT WARRANTY GARDNER DENVER PETROLEUM PUMPS GENERAL PROVISIONS AND LIMITATIONS 3. Repairs are warranted for 90 days from the Gardner Denver (the "Company") warrants to each date of delivery, for the workmanship and original retail purchaser ("Purchaser") of its new materials of the new parts installed.
  • Page 39 PRODUCT WARRANTY GARDNER DENVER PETROLEUM PUMPS All costs of transportation of product or parts CIRCUMSTANCES, WHETHER CONTRACT, claimed not to be as warranted and, of repaired or TORT OR OTHERWISE, SHALL THE COMPANY’S replacement parts to or from such service facility shall TOTAL LIABILITY ARISING IN CONNECTION WITH be borne by the Purchaser.
  • Page 40 For additional information contact your local representative or Gardner Denver Compressor and Pump Division, 1800 Gardner Expressway, Quincy, Illinois 62301 Customer Service Department Telephone: (800) 682-9868 FAX: (217) 224-7814 Sales and Service in all major cities. Specifications subject to change without notice. For parts information, contact Gardner Denver, Copyright ©...

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Pzk – 10”Pzl – 11”Pzh – 8”Pzj – 9”Pxl

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