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- C2500Q QUINTUPLEX
- Operating And Service Manual
Gardner Denver C2500Q QUINTUPLEX Operating And Service Manual
Summary of C2500Q QUINTUPLEX
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Ecn 1058968 gardner denver ® 300cmc996 revision c april 2011 well servicing pump model c2500q quintuplex operating and service manual.
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Page i c2500 well servicing pump maintain pump reliability and performance with genuine gardner denver parts and support services gardner denver ® genuine pump parts are manufactured to design tolerances and are developed for optimum dependability. Design and material innovations are the result of y...
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Page ii 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 essent...
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Page iii table of contents maintain pump reliability and performance with genuine gardner denver parts and support services ........................................................................................................... I instructions for ordering repair parts ..............................
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Page iv index crankshaft assembly .................................. 25 crankshaft replacement ............................ 26 crosshead assembly ….............................. 23 crosshead guide and stay rods …............ 24 daily routine maintenance schedule.......... 18 danger notices, section ...
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Page v 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 ..........
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1 section 1 danger notices danger read and understand the following danger notices before moving or operating the pump or any pump package unit equipment. Reciprocating pumps are machines capable of producing high fluid pressures and flow rates and are designed to be used with proper care and cautio...
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2 • wipe their hands and the hammer handle and maintain a firm grip on the handle to avoid losing control of the hammer while swinging and striking. • carefully swing the hammer to avoid striking themselves, another person and objects other than the targeted lugs or hammer bar. • avoid swinging the ...
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3 danger failure to follow safe and proper pump, pump package or component lifting or moving procedures can lead to personal injury, death and /or equipment damage from shifting, falling or other unexpected or uncontrolled equipment movements. Make sure the hoist, lift truck, ropes, slings, spreader...
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4 operating a pump against a blocked or restricted discharge line can produce excessive pressures in the entire discharge system, which can damage or burst discharge system components. Danger never operate a pump without a properly sized pressure relief valve or working overpressure shutdown in the ...
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5 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 ...
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6 equipment damage due to explosion, fire, extreme cold or chemical attack. Never operate a pump that 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 t...
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7 vehicles. A broken, cut or otherwise burst hose can release pressurized fluid that may cause personal injury, death and/or equipment damage. 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, ...
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8 nozzle, gun, etc. To pry loose material off items being cleaned. Before starting operation in a 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, e...
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9 section 2 design, description and specifications introduction the gardner denver c2500 is a high horsepower, high rod load multi-purpose pump for various applications such as oil and gas well fracturing, acidizing, and cementing. The issue of personnel safety is the most important topic covered in...
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10 section 4, "service procedures," describes the various assembly / disassembly procedures. Section 5, “trouble–shooting,” describes possible problems, causes and solutions related to pump performance. Section 6, “rebuilding data, recommended running clearances and torques,” presents information us...
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Page 11 power end and gear reduction unit lube system (figure 2-1 and figure 2-2) both the internal gear reduction unit and the power end have one common lube oil inlet. The power end inlet is located one end of the lube manifold forward of the gear cover. The inlet is a 1.25” nptf tee that divides ...
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Page 12 fluid end (figure 2-3) this fluid end incorporates the traditional flange-mounted fluid end design, which simplifies installation and removal by simply removing the stay-rod nuts. These stay-rod nuts must be made-up tight and remain tight during operation. (see torque requirements on page 34...
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Page 13 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 r...
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Page 14 section 3 preparation, operation and maintenance danger read and understand clearly all safety rules and precautions before attempting to operate the pump. This section deals with pump preparation after shipping and storage of the pump, user built lubrication system and its specifications, p...
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Page 15 7. Bolt brackets to pump, using 7/8” – 9unc grade 8 bolts. 7. When connecting the suction line to the suction manifold, provide support to the suction line independent of the pump suction manifold. Fluid adds weight to the suction line. 8. The use of suction stabilizers is always recommended...
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Page 16 figure 3-1 indicates api-gl5 oil grades recommended for use in the pump power end and the gear reducer lube system. Crankcase operating temperature ranges and minimum startup temperatures for each listed grade of oil for various inlet or sump temperature ranges. Figure 3-1: lubricant recomme...
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Page 17 assist the user, the following guidelines are presented for the maintenance personnel to follow during the critical startup and break-in period: 1. Fill the lube oil reservoir with recommended grade of oil. See "power end lubrication" on page 15 and figure 3-1 above. 2. Fill the packing lube...
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Page 18 trouble free operation of this pump. It is highly recommended that the customer set up a maintenance program during the run-in period. The periodic maintenance data should be recorded and kept with other pump documents. The following recommendations, based on previous experience, should serv...
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Page 19 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. Vistac #68x 10 ° f ...
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Page 20 section 4 service procedures this section describes various assembly and disassembly procedures necessary for pump servicing or parts replacement. The general requirements and safety rules section is a reminder for the maintenance personnel of the critical importance of safety rules and prec...
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Page 21 notice while the stay-rod are available to inspection, check loose stay-rods and cracked threads in all stay-rods. The connection between the power end and the fluid end is a critical one. To reinstall the fluid end proceed as follows: 1. Check all twenty stay rods for thread damage or crack...
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Page 22 11. Install and hand tighten the packing nut to align the packing in the bore. 12. Loosen the packing nut to allow for installation of the plunger. 13. Grease plunger, insert through the suction cover hole into the packing. It may be necessary to bump the plunger through the packing with a s...
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Page 23 12. Be sure the o-ring is installed on the seat and snap the valve seat into the taper by hand to fit tightly. 13. Place the valve on the top of the valve seat. 14. Bump the seat into the taper 2-3 times with a heavy bar to make the fit tight. 15. Inspect the valve guide bore diameters for e...
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Page 24 housing is in highest position. Using a socket and impact wrench or special conn-rod wrench, remove bottom 3 lock-nuts. 5. Remove three nuts on top of conn-rod. Figure 4-3 crosshead assembly 6. While moving the bearing housing in an up and down motion, pull the crosshead assembly forward, ou...
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Page 25 gear reduction unit notice this assembly is a timed gear set, and should be changed as a gear set. If one gear is changed, both should be changed. If one gear only is changed, the gears must be timed. 1. Disconnect the input pinion shaft from the transmission or drive shaft. 2. Disconnect th...
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Page 27 crankshaft replacement 1. Determine which is no. 1 throw. Place crankshaft in a vertical position, either in special fixture or a bull-gear lying flat on the ground, with the no. 1 throw down toward or nearest the ground. 2. Heat the bearings uniformly, and install the second bearing from th...
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Page 28 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. Install the ...
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Page 29 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...
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Page 30 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. Check and tighte...
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Page 31 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. Clean and polish shaft or replace wear sleeve....
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Page 32 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 ...
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Page 33 problem possible cause suggested action catastrophic failures: 8. Low oil level in sump. 1. Check oil level frequently, broken shafts, and add oil as required. Bent rods, etc. (continued). 9. Contaminated oil in sump. 9. Check oil condition frequently. 10. Cavitation shock loading. 10. See c...
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Page 33 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” /...
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Page 34.
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Page 35 recommended torques for c-2500q pump maintenance torques foot pounds . Description fastener with loctite with antiseize gear covers, misc. ............................................3/8”-16 16 main bearing retainer plate screws (gr. 8)………1/2”-13 64 .............................................
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Page 36 product 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 suc...
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Page 37 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 ...
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Page 38 this warranty shall not be effective as to any claim which is not presented within 30 days after the date upon which the product is claimed not to have been as warranted. Any action for breach of this warranty must be commenced within one year after the date upon which the cause of action oc...
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For additional information contact your local representative or gardner denver inc. 4747 south 83 rd 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 ...