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- Operating And Service Manual
Gardner Denver GD-3000 Operating And Service Manual
Summary of GD-3000
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Ecn 1058968 gardner denver ® 3-1-618 revision d april 2011 well servicing pump model gd-3000 operating and service manual.
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3-1-618 page i gd-3000 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 r...
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3-1-618 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 personne...
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3-1-618 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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3-1-618 page iv index crankshaft assembly .................................. 26 crosshead assembly ….............................. 24 crosshead guide and tie rods ….............. 25 daily routine maintenance schedule.......... 19 danger notices, section 1................. 1 covers and guards...........
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3-1-618 page v list of illustrations figure # description page figure 2-1 gd 3000 pump...................................................................................... 9 figure 2-2 gd 3000 power end .............................................................................. 10 figure 2-3 gd ...
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3-1-618 page 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 ca...
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3-1-618 page 2 • carefully swing the hammer to avoid striking themselves, another person and objects other than the targeted lugs or hammer bar. • avoid swinging the hammer above shoulder height. Valve seat pulling danger the following precautions must be observed by operators and maintenance person...
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3-1-618 page 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, sli...
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3-1-618 page 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 shu...
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3-1-618 page 5 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 mo...
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3-1-618 page 6 never operate a pump which 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 than a few drops per minute of packing weepage, is observed. ...
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3-1-618 page 7 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 han...
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3-1-618 page 8 before purchasing wands, nozzles, guns, connections, hoses, etc., manufacturers of these components should be contacted for detailed information on the design and safety features incorporated in their products. After careful study of various manufacturers products, we recommend that o...
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3-1-618 page 9 section 2 design, description and specifications introduction the new gardner denver gd 3000 is a high horsepower, high rod load multi-purpose pump for various applications such as oil and gas well fracturing and acidizing and potentially as a light weight drilling pump. The pump was ...
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3-1-618 page 10 section 3, "pump preparation, operation, and maintenance," addresses the issues of preparing the pump for operation after shipping or storage, the lubrication system design and specifications, the new pump run-in procedures, and the periodic routine maintenance schedule. The recommen...
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3-1-618 page 11 figure 2-3 gd 3000 power end top view notice the direction of rotation must be such that the top side of the crankshaft is moving towrd the fluid end. The cast crosshead guide connects the pump power frame and the fluid cylinder and the whole assembly is held together by eight (8) ti...
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3-1-618 page 12 power end and gear reduction unit lube system (figure 2-2, figure 2-3, and figure 2-4,) both the gear reduction unit and power end have individual lube oil inlets. The power end inlet is located at the rear of the pump. The inlet is a 1-1/2” nptf tee which divides the lube flow betwe...
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3-1-618 page 13 fluid end (figure 2-5) this fluid end incorporates a modern through stud design, which eliminates the weight of the traditional flange fluid ends and simplifies installation and removal of tie bolt nuts. Hytorc turbine style nuts are used to provide much improved method of fastening....
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3-1-618 page 14 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...
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3-1-618 page 15 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 specifica...
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3-1-618 page 16 8. Maintaining a slight amount of upward tension on the fluid end, check the gap beneath the fluid end supports. 9. Select the proper number and thickness of blocks and/or shims to fill the gap under the supports. 10. With blocks and/or shims in place, tighten the four bolts on the f...
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3-1-618 page 17 listed grade of oil for various inlet or sump temperature ranges. Figure 3-1 lubricant recommendations plunger / packing lubrication the fluid end plungers are lubricated from a separate lubrication pump through the stuffing box. The lubrication pump, hosing, and check valve to the s...
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3-1-618 page 18 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," and figure 3-1, page 16. 2. Fill the packing lube reservoir with ...
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3-1-618 page 19 periodic routine maintenance schedule performance of the periodic routine maintenance tasks, described in this section, will ensure long, economical, and trouble free operation of this pump. It is highly recommended that the customer set up a maintenance program during the run-in per...
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3-1-618 page 20 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...
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3-1-618 page 21 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 ...
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3-1-618 page 22 notice the procedure for fluid end installation is presented separately due to the special and critical nature of the connection between the power end and the fluid end. To reinstall the fluid end proceed as follows: 1. Check all eight tie rods for thread damage. If replacement is re...
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3-1-618 page 23 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. Insert the plunger through the suction cover hole into the packing. It may be necessary to bump the plunger through the packing with...
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3-1-618 page 24 5. Remove the suction valve spring retainer, suction valve and valve spring. 6. Remove the suction valve seat or discharge valve seat with a seat puller and a seat puller jack. These tools are available from gardner denver. 7. Clean the valve seat deck thoroughly. 8. Be sure the o-ri...
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3-1-618 page 25 figure 4-3 crosshead assembly 7. Remove journal bearings from the rod and rod cap. 8. Slide crosshead and rod assembly forward until journal end of rod is ready to enter the crosshead guide bore. 9. Place heavy plastic or cardboard under end of rod as it enters bore to prevent scorin...
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3-1-618 page 26 6. Using the tie rod wrench (refer to the special tools section in the parts manual) remove the tie rod. Note: the tie rod should be supported either with a hoist or another technician. Gear reduction unit notice this assembly requires factory tooling for helical gear timing during r...
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3-1-618 page 27 14. Lift the crankshaft until it is free of all main bearings. Continue until bearing faces of crankshaft reaches next bearing. If crankshaft does not slip through bearings freely, push rollers into race. If bearings are extremely loose and worn, it may be necessary to install spiral...
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3-1-618 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. Inst...
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3-1-618 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 da...
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3-1-618 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 an...
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3-1-618 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...
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3-1-618 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 overt...
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3-1-618 page 33 problem possible cause suggested action catastrophic failures: 8. Low oil level in sump. 8. 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. 1...
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3-1-618 page 34 section 6 rebuilding data, recommended running clearances and torques rebuilding data for gd 3000 pump (in.) pump stroke 11 inches crankshaft throw diameter............................................... 7.7485/7.7500 crankshaft shaft diameter at main bearings..................... 19...
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3-1-618 page 35 recommended torques values for gd-3000 _ foot pounds_________ description fastener with loctite with antiseize plunger clamp bolts……………………………….. 1/2”-13 58 main bearing retainer bolts............................... ½”-13 58 thrust bearing retainer .......................................
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3-1-618 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 ...
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3-1-618 page 37 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 be as warranted. Labor shall be limited to the amou...
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3-1-618 page 38 no statement, representation, agreement, or understanding, oral or written, made by any agent, distributor, representative, or employee of the company which is not contained in this warranty will be binding upon the company unless made in writing and executed by an officer of the com...