GARDNER

15-600
2ndEdition

DENVER

INSTRUCTION & SERVICE

MANUAL

TRIPLEX
SINGLE ACTING PUMP
8 STROKE

- PZ8

9 STROKE

- PZ9

11 STROKE

- PZL

WARRANTY

Subject to the terms and conditions hereinafter set forth, Gardner-Denver Company (the
Company) warrants products and parts sold by it, insofar as they are of its own manufacture,
against defects of material and workmanship, under use and service in accordance with Companys
written instructions, recommendations and ratings for installation, operating, maintenance and
service of products, for a period of three months from the date of initial use, provided that such
three month period shall in no case extend beyond one year from the date of shipment by
Company. THIS WARRANTY
IS LIMITED TO THE REPAIR OR REPLACEMENT, AS
COMPANY MAY ELECT, OF ANY DEFECTIVE PARTS, REGARDING WHICH, UPON
DISCOVERY OF THE DEFECTS, THE PURCHASER HAS GIVEN IMMEDIATE WRITTEN
NOTICE. Installation and transportation costs are not included. Company shall have the option
of requiring the return to it of the defective material, transportation prepaid, for inspection.
Because of varying conditions of installation and operation, all guarantees of performance are
subject to variation of 3%. COMPANY DOES NOT WARRANT THE MERCHANTABILITY
OF ITS PRODUCTS AND DOES NOT MAKE ANY WARRANTY, EXPRESS OR IMPLIED,
OTHER THAN THE WARRANTY
CONTAINED HEREIN. Company has not authorized
anybody to make any representation or warranty other than the warranty contained herein.

TABLE

OPERATING & MAINTENANCE

Location . . . . . . . . . . . . . .
Suction Line . . . . . . . . . . . .
Relief Valves . . . . . . . . . . .
Surge Chamber . .. . . . . . . . .
Starting A New Pump . . . . .
Lubrication & Capacities . . .
Oil Filter . . . . . . . . . . . . . .
Heat Exchanger . . . . . . . . . .
Direction of Rotation . . . . . .
Operation . . . . . . . . . . . . .
Sizes & Ratings Charts . . . . .
SERVICE INSTRUCTIONS
Jackshaft, Bearings & Seals .
Connecting Rods . . . . . . . .
Eccentric & Gear Assembly .
Eccentric Cam Bearings . . .
Main Bearings . . . . . . . . . .
Crosshead Pins . . . . . . . . .
Push Rods . . . . . . . . . . . .
Crossheads, . . . . . . . . . . .
Crosshead Slides . . . . . . . .
Oil Stop Heads . . . . . . . . .

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INSTRUCTIONS
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POWER
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END.
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2
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3
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...10
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5
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OF CONTENTS

SERVICE INSTRUCTIONS FLUID END .

Valve Chambers . . . . . . . . . . . . . . . . . .
Liner Clamp & Liners, . . . . . . . . . . . . . .
Pistons . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rod . . . . . . . . . . . . . . . . . . . . . .
Piiton Washing System . . . . . . . . . . . . . .
Maintenance of Valves . . . . . . . . . . . . . .
Suction Strainer . . . . . . . . . . . . . . . . . .
Recommended Running Clearances . . . . .
Manufacturing Fits . . . . . . . . . . . . . . . .
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Recommended Torques .,....
Methods of Preparing PZ Pumps for
Prevention of Darnage During Shipment

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. . . 12
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...12
...12
...12
...12
...12
...13
, . . 14
...14

. . . ...14
. . . . . . 15

Recommended Typical Suction & Discharge Piping

Arrangement (PZ8, PZ9&PZL).
. . . . . . . . . ...17
Sectional View of Typical Model PZ Pump . . . . . . . . 18
PZ Pump Outline

. . . . . . . . . . . . . . . . . . . . . . ...19

Eccentric &Bearings

15-600

Page 1

-PZ

Pump. . . . . . . . . . . . ...20

OPERATING
FOR PZ8, PZ9

AND MAINTENANCE
INSTRUCTIONS
& PZL SINGLE ACTING POWER PUMPS
FOR MUD SERVICE

Reference to Pints List covering the model pump being serviced is recommended
with this Instruction Book.

in connection

Repair Parts Lists with Sectional Views are available from any Gardner-Denver Company Sales
and Service Office listed on the back cover When ordering parts always give size and serial
number of pump. Always use genuine Gardner-Denver parts For efficient factory- trmnedservice,
consult a Gardner-Denver service specialist.
When working
side. Pressure
recommended
agmnst pistons

on any pump, be certain there is no fluid pressure on either suction or discharge

on fluid end might move pump and cause damage or injury to personnel It is
that all suction valve covers be removed to avoid fluid pressure building up
or plungers.

If drive is not to be removed, it is recommended

prevent accidental starting of pump.

that air line to clutch be disconnected

to

LOCATION Pum should be set level and solidly supported. The drive should be accurately aligned. Pump should be placed
as close to the slush
h pit as possible to keep the suction line short and direct. Locate pump as low as possible to maintain a
minimum suction lift to the centrifugal charging pump which is used because of the high speed of this type of mud pump.
SUCTION LINE Suction pipe or hose to charging pump should be a minimum of 12 diameter and as short as possible.
Suction line should slope up toward the charging pump at uniform grade to prevent air pockets being formed. Suction
line must be absolutely tight as any air leaking into the line will reduce the capacity of the pump and cause a hydraulic
hammer or knock. If it is necessary to have bends in the suction line they should have long radius sweeps and be kept to
a minimum in quantity,
Suction line should be supported

near centrifugal charging pump to keep strain from breaking the casing at suction flange.

At least one section of hose in the suction line is desirable. to isolate pulsations or vibration. Total suction line should be
as short as installation conditions permit. THIS IS IMPORTANT.
A suction strainer is recommended for the suction line of every pump. It must be checked frequently and cleaned whenever
necessary. A commercial strainer may be installed in suction line ahead of the pump.
It is recommended

that a 50 PSI

gaugewith a needle valve for protection be

This gauge
if pump
will indicate
is charging or ifsuction valves are not working properly.

RELIEF VALVES The pump should be protected from excess discharge pressure by a 3 shear type relief valve. This
valve should be installed in a vertical position in a tee mounted directly onto either end of discharge manifold. Never install
a shutoff valve in the line between the relief safety valve and the pump discharge manifold. If more than one pump is used,
a pressure release valve should be furnished for each pump. A hand operated pressure release valve should be installed
discharge line following shear 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 for protection to surface equipment and to reduce
pulsations when pumping gaseous mud. A nitrogen charged pressure bag type surge chamber is recommended. The surge
chamber must be kept properly charged, as instructed by the manufacturer.
STARTING A NEW PUMP It is necessary that drive be arranged to turn the pump in the direction indicated by arrow
shown on the sectional view in this book, on outline prints, and cast on pump frame. This provides for crosshead load to be
carried on the lower slide. This means better lubrication and quiet operation. Pump must run in indicated direction because
lube oil pump used to force oil through falter will pump in one direction only.
pumps are shi ped from the factory without oil in the crankcase. The hood should be removed and the power end examined
and cleaned lf
necessary. The pump may have been in storage or in the yard for some time, and as a consequence, dirt may
have entered the crankcase. Drain all water accumulated in the bottom of the crankcase. Fill crankcase with oil of proper
grade to the proper leveL Quantity shown on lubrication data plate indicates the approximate oil requirement. AI1 nuts and
cap screws should be checked for tightness.
It is recommended that fluid end of the pump be primed to prevent excessive wear on the fluid pistons and liners when
IT LUBRICATES PISTONS IN LINERS.
starting. PRIMING IS JMPORTANT!
pump should be started slowly but not run below half of rated speed. Recheck oil level as it may be necessary to add a small
quantity of oil to compensate for that adhering to the walls of the crankcase and the moving parts. The pump may then be

15-600

Page 2

gradually brought up to full speed and full working pressure. Check all joints in the suction line to be sure there are no air leaks.

LUBRICATION

All power

end working parts are lubricated by oil in the crankcase. Check oil level frequently.

The use of SAE 90 gear oil or type AGMA

5EP lead naphthenate gear lubricant is recommended

for crankcase lubrication.

Selection of oil is to be taken from the recommendations given above and on the pump nameplate. Local conditions and
practice may also influence the selection. Essential additives are foam and oxidation inhibitors. Oil is to be added as required
to maintain oil level near top of oil level indicator on the side of the frame.
Oil is constantly circulated through a renewable element filter and then through a heat exchanger, when one is used, by
means of a rotary pump driven from the main gear. oil is discharged into an elevated oil feed trough, from which it is conducted to jackshaft and main bearings. oil also flows from the trough to lubricate the connecting rod bearings.
Operating temperatures of the oil should be kept below

1700 F. to reduce oxidation.

Time between oil changes depends upon local and/or operating conditions. Under normal circumstance% if the crankcase
is ke t clean, it should not be necessary to change oil more than once in 1000 hours of operation. Many o erators change
oil after each well drilled. Oil should be changed if found to be dirty or contaminated with mud or water.This is especially
important for the PZ pump, as the oil lubricated roller bearings will be damaged by contamination. An oil change is corncrankcase capacities are as follows:
paratively inexpensive, as the approximate
PZ8 . . . . . . . . . . . . ..41
Gallons
PZ9.
, . . . . . . . ..5
Gallons
PZL.
. . . . . . . . . . . ..85
Gallons
In order to assure proper lubrication

the pump should not be run under 10 RPM for more than a few minutes at a time.

The oils normally used in large mud pumps are quite viscous at lower temperatures. When starting cold, the pump should be
started slowly and brought up to operating speed slowly. This practice will assure proper lubrication of all working parts
before pump is fullyloaded.

OIL FILTER

A replaceable element oil filter is located inside the pump crankcase. Filter mounting flange is on the
outside, making it possible to replace the element by removing end plate. Only the oil within the filter case will be spilled
when element is withdrawn.
Filter element should be replaced each time crankcase oil is changed or every 1000 hours of operation.
Filter element is protected
setting is 20 PSI. -

from excessive internal oil pressure by a relief valve between it and the oil .pump.
. Relief valve

oil flows through the oil filter before going through the heat exchanger.

HEAT EXCHANGER (Models PZ8 & PZ9) A bronze heat exchanger is provided to keep crankcase oil temperature at
160 F. by means of an automatic water control valve. This valve has a heat sensing probe in the crankcase oil, and it
monitors water to the heat exchanger to maintain oil temperature within close limits.
Water must be drained from the heat exchanger during freezing weather. Ruptured water tubes will admit water into the
oil, with resulting damage to working parts of the pump.
Cooling

water can be drained from

the heat exchanger by removing water connections

and blowing compressed

air into

UPPer opening. Water will then flow from the lower opening. Air iS necessary, as water will not otherwise drain due to small
size of tubes, capillary attraction, and the horizontal position of the heat exchanger mounting.
Water should not be admitted to the heat exchanger as long as oil temperatures do not exceed 160 F, A dial thermometer
is standard equipment on the PZ pump.
Salt water can be used for cooling.
when they have been eaten away.

Zinc anode plugs are provided for corrosion

protection.

These plugs are to be replaced

DIRECTION OF ROTATION
The PZ pump is to be driven in one direction onl as shown by arrow on sectional view,
outline drawing and cast on pump frame. The oil pump which forces crankcase oil through the filter and heat exchanger
is a nonreversible pump.
Running pum
in the prescribed
will be carrie d on lower slide.

direction

will also result in proper lubrication

and quiet operation as-load

on crosshead

OPERATION For normal drilling operation, the pumps are to be run at the ratings listed in the following tables. In no
case should pressure exceed that shown for each diameter piston to do so would subject working parts to operating
loads in excess of those for which they were designed, resulting in reduced life.

15-600

Page 3

SIZES AND

Cylinders
Quantity

Diameter

RATINGS

Displacement
Stroke

G.P. R

MODEL

PZ8

Maximum
P.S.I.

G.P.M.

750

H.P.

Piston
Load

TRIPLEX

Pump
RP.M.

Jackshaft
R.P.M.

Input
H.P.

MUD PUMP

6-1/4

3.19

526

2200

67,500

165

742.5

750

2.94

485

2385

67,500

165

742.5

750

5-1/2

2.47

407

2843

67,500

165

742.5

750

2.04

337

3433

67,500

165

742.5

750

4-1/2

1.65

273

4238

67,500

165

742.5

750

1.31

215

5381

67,500

165

742.5

750

Weight Complete pump

Gear Ratio . . . . . . . .
Length Over Skid, . . .
Width Over Skid . . . . .

MODEL

PZ9

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1000

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H.P.

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TRIPLEX

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. 21,650 Lbs.
. . . 4.5tol
. . .
193.62
89"
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MUD PUMP

6-1/4

3.58

558

2770

85,000

156

699

1000

3.30

515

3000

85,000

156

699

1000

5-1/2

2.77

432

3570

85,000

156

699

1000

2.29

357

4330

85,000

156

699

1000

4-1/2

1.86

290

5340

85,000

156

699

1000

.....
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1600

TRIPLEX

Weight Complete Pump

Gear Ratio . . . . . . . .
Length Over Skid . . . .
Width Over Skid . . . . .

MODEL

PZL

H.P.

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. 26,500 Lbs.
. 4.48 to 1
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224.12
96,,
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MUD PUMP

11

5.50

715

3454

132,993

130

569

1600

6-1/2

11

4.74

616

4006

132,993

130

569

1600

11

4.04

525

4702

132,993

130

569

1600

5-1/2

11

3.39

441

5595

132,993

130

569

1600

Weight Complete Pump

Gear Ratio . . . . . . . .
Length Over Skid . . . .
Width Over Skid . . . . .
Width Over Jackshaft .

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15-600

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Page4

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40,500 Lbs.
..4.38tol
. . .
222.5
. . . . 96.0
. ...104.0

SERVICE

INSTRUCTIONS

POWER END

Remove hood and crosshead inspection plates for access to working parts. Before working on inside of crankcase, it is
Eoil
necessary to drain the oil. Oil pump mounting brackets and piping connections are below the
level.
Mark all parts during dismantling so they can be returned to their original position
It is highly recommended

during reassembly.

that pump be removed to a machine shop if major work is to be done on the power end.

JACKSHAFT

To remove the ackshaft, it is necessary to remove all sheaves from the jackshaft. Then remove bearing
end plates and bearing housings from both sides of pump. Su port each end of ackshaft while removing bearin housings.
The jackshaft can be moved horizontally until the pinion teet h clear the teeth o f the eccentric gear. The jacksha ft can now
be removed from either side of the pump.
The jackshaft bearings are of the straight roller t pe with the roller and cage assembly held in the flanged outer race. The
inner race is not flanged. The outer race with roller assembly will slide over the inner race which remains on the jackshaft.
Both bearings are identical.
The straight roller bearings permit the jackshaft to float endwise. Thrust loads are carried on the spherical 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 point where race is discolored. Be careful not to damage the bearing spacer ring between the inner race and the shoulder
on the shaft.

BEARING HOUSING
GASKET

BEARINGSPACER RING

JACKSHAFT

JACKSHAFT

SEAL WEAR SLEEVE

FIGURE

If the jackshaft
housing.

1.

JACKSHAFT

BEARING

INSTALLATION

bearing is to be replaced, the outer race and roller assembly can be driven or pressed out of the bearing

The jackshaft bearings should be replaced if any of the rollers or races shows damage or if they are excessively worn. A
noisy bearing indicates bearing damage, re uiring replacement. Check clearances by inserting feeler gauge between the roller
and inner race with bearing assembled on th e shaft and in the housing. This check can be made with the bearing temporarily
assembled out of the pump, but with inner race on jackshaft. See recommended running clearances on page 14.

15-600

Page 5

To mount new bearings, heat the inner race in oil to about 300 F. and slip it on the shaft against the bearing spacer ring.
Be certain the spacer ring is in place with the chamfered end of the bore over the large fillet on the jackshaft. The inner
race and the spacer are to be assembled snugly against the shaft shoulder. The shaft can then be reinstalled in the frame.
To mount a new oil seal wear sleeve, heat the sleeve in oil to about 300

F. and slip it on the shaft.

To reassemble the jackshaft in the pump, it is necessary to reverse procedure of removal. The teeth of the pinion can mesh
in only one direction, therefore, the jackshaft is not interchangeable end for end in the pump unless gear and eccentric
assembly is also reversed. Reversal of the complete gearset is perrnissable 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 falter from original position to the
opposite side of the frame and repipe as required.
Recommended direction of rotation of the
that when viewing from the hood opening,
ends of the pinion teeth point toward the
BE REVERSED. Pump should be run in
and frame. Apex of teeth will follow after

pump provides that inner ends or apex of gear and pinion teeth lead. This means
the inner ends of the gear teeth point upward toward the jackshaft and the inner
gear. Gears may be reversed, but direction of rotation of the pump MUST NOT
the direction shown on sectional view and indicated by arrow on outline print
gearset has been reversed.

After jackshaft is in place with the pinion in mesh with the gear, install the bearing housings with the outer bearing race
and roller assemblies in them. Be careful to keep dirt from the bearings during assembly. The housing is to be started on
the bearing and in the bore of the frame and lightly driven in. Be sure the gasket is on the housing. Long threaded studs
may be used to pull the housing into the frame bore. It is well to work both housings at the same time after they have
been well started over the bearing inner race. This will minimize end thrust on the gear teeth.
Before assembling bearin plates into the frame, the bearing oil troughs should be installed. The bearing housing can be
kin it easy to level oil trough properly. Top of oil trough is to be level.
rotated in the frame, making
The outer
ease seals are to be placed in the bearing end plate after it is bolted to the bearing housin and frame. Coat
inside ofoil seal
liberally with bearing grease. The outer seal is to be installed with garter spring to inside,

toward bearing.
f
Permanently bolt jackshaft bearing housings and their end plates to the frame,

CONNECTING RODS The connecting rods are split into body and cap, and bolted
struction is used to simplify installation and/or removal of eccentric and gear assembly.

together without shims. This con-

Upper connecting rod bolt is inserted from the cap side to avoid
interference with jackshaft. Lower
bolt is inserted from body side to
make nut easily accessible.
Crosshead pins with bearing inner
races can be removed without removing connecting rods.
Crosshead pin bearings can be removed and replaced by means of a
puller available from the factory.
Refer to parts list.
Always protect crosshead slide in
frame by placing a block of wood
under small end of connecting rod.
If slide should be accidently damaged, be certain to stone darnaged
area so no metal projects above slide
surface. Do not use emery cloth.
When caps are removed, the bodies
of the connecting rods can be supported by wiring or tying them to
cap screws temporarily driven into
hood ledge above them. Do not
darnage hood gasket surface. See
Figure 2.
Remove eccentric bearing retainers from the connecting rod body and cap before cap is removed. Replace retainers after
connecting rods have been reassembled. Be sure to wire the cap screws securely.
Connecting rod bolt nuts are to be tightened to recommended
against nut by hand and then tightened 1/3 to I/2 turn.

15-600

torque shown on page 14. The Pal locknuts are to be driven

Page 6

ECCENTRIC

AND GEAR ASSEMBLY

See sectional view of pump, Figure 9, on page 18.

Important Be sure to remove oil pump drive pinion when removing or replacing eccentric and gear assembly
bending oil pump shaft when gear is moved.

to avoid

Eccentric and shaft are made in

one piece.
Eccentric and gear assembly is to
be removed from the frame for the
following reasons:
Assembly is to be reversed after
gear is worn.
Gear is to be replaced.
One or more eccentric bearings are
to be replaced.
Eccentric is to be replaced,
Procedure for Removal
1.

Remove connecting rod caps

and support the rods.

2.

Remove large main bearing

plates from frame and bearing cartridges.

3.

Remove frame clamp

over main bearings.

4.

Remove frame spacer blocks by moving them sideways, as they are keyed to frame. Be sure the spacer blocks are
marked to assure reassembly in original position.

5.

Loosen main bearing retainer plate screws in ends of eccentric

about 1/4 space between eccentric shaft and retainer plates.

6.

Spread frame slot approximately 1/64 by means of hydraulic or screw jacks (Figure 3). Be sure to protect faces of
frame slots against damage from jacks. This is important.

7.

Support eccentric

8.

Connect a 10,000 PSI hydraulic oil pump (BlackHawk P76 or equivalent) to 3/8 pipe tap in end of eccentric shaft
after removing protective plug. There is a clearance hole through the retainer plate.

9.

Hydraulic pressure will loosen bore of the main bearing on the tapered shaft.

10.

With bearing loose on shaft taper, the retainer plates should be removed. Bearing cartridges are now to be removed.
They are heavy, so suitable provisions must be provided to handle them. Lifting devices shown in Figure 4 are useful
in disassembly 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.

studs

and gear assembly in original position

shaft. Do not remove the retainer plate screws. Leave

by means of a sling, hoist or blocks

It will be necessary to raise or lower and shift the suspended connecting

(Figure 3).

rods to clear the eccentric during removal.

After eccentric assembly has been removed from the frame, remove outer cam bearings from their inner races. The y
might slide off and be damaged or injure someone.

12.

Set eccentric

13.

It is essential that every effort be taken to protect all roller bearings from dust and dirt by keeping them wrapped in
sheet plastic or clean paaper. Be certain to cover the bearings if they are to remain out of the frame for hours, such
as overnight.

ECCENTRIC

assembly in a clean place so work can proceed

CAM BEARINGS

These bearings are mounted

15-600

on it.

on, and remain with the eccentric and gear assembly during

Page 7

dismantling and reassembly of the power end. The bearings are of the cylindrical roller type, with the rollers retained in
the outer race. The inner races are shrunk on the eccentric cams,
The outer races with rollers will slide off the end or outer eccentric cam bearing inner races, The center bearing is slipped
over the adjacent eccentric cam after its bearing race has been removed.
Inner bearin races can be removed by heating evenly all around with torches. If bearings are to be used again, be careful
not to disco l or the inner race with excessive heat. Spit-frying hot is sufficient. Handle with gloves.

d
.
1,0

~, 56

6.0

38

7.0

DRILL
TnRU
ONE
ONE HOLE ,

: N.u

w+

8UNC
THREAD
FOR
EYEBOLT

1-

:. =.

WELD

2.0
-4.0

The center bearing inner race is slipped over the

adjacent end cam while it is still hot and after the
end bearing inner race has been removed.

-1

10

Inner races are equipped with an end ring. They

must be mounted on the correct end of each inner
race. Refer to sectional view showing eccentric and
bearings for proper location of inner race end ring.

C74625

..
..

FOR

MAIN BEARINGS These bearings are of the

double row spherical type. Inner race has a tapered
bore. Main bearings
can be replaced without removing eccentric assembly from the pump and without disturbing connecting rods.

PZ8 ONLY

Remove bearings with cartridges from the eccentric

shaft and frame as outlined in above procedure covering removal of eccentric and gear- assembly. Be
sure to support eccentric securely in its original location. Remove oil
pump gear to protect oil pump
shaft as main gear might move during this operation.

--4-

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 from the cartridge.

..
..

C73507

..

.
&
.

FOR

PZ9

Antifriction bearings should not be removed from

their protective wrapping until ready to be mounted.
Do not remove protective grease from rollers of new
bearings. It will not contaminate crankcase oil.

ONLY

11/8 7 uNC

-.

Procedure for Mounting

1.

When ready to mount, unwrap bearing and

stand it upright on a clean flat surface with
bore horizontal.

2.

Determine and record internal clearance by

checking with feeler between upper rollers and
inside diameter of outer race. Check both rows
of rollers.

3.

Wipe outside

THREAD

FOR EYEBOLT

.-=. :
.- ,,

1.0

5.54

WELD

2.0

These bearings are not preloaded and must have

running clearance. Check with feeler at bottom and
between inner race and rollers. See page 14
for
recommended running clearance.

7,0 A

4.0

.38

8.0

DRILL

THRU

ONE HOLE

1 DRILL THRU
2 HOLES

,
45.
2.28

1.0

$.*R

3.20 y

FOR

apply athin

C74911

PZL ONLY

FIGURE 4. MAIN BEARING CARTRIDGE

LIFTING & LOCATING DEVICES

15-600

Page 8

diameter

of bearing clean and

coat of Crankcase Oil.

4.

Wipe bore of bearing cartridge clean.

5.

Push bearing snugly onto taper of shaft by

hand only, without cartridge.

6.

bearing overhang with a

Check and record
depth micrometer or with straight edge and
feeler blades. This can be done with eccentric
in the frame, or with eccentric out of the
frame as shown in Figure 5.

7.

Determine the thickness of shim pack required

for drive-up by subtracting .067 for PZ8, .075
for PZ9, or .090 for PZL from the bearing
overhang. For example (Model PZ9 ): if the overhang is .100, the shim pack thickness is .100
minus .075 equals .025.

8.

Lay bearing on a flat clean surface with small end

of bore down.

9.

Lower cartridge over bearing, using light blows

with a soft mallet if needed. Bearing cartridge is
interchangeable end for end.

10.

Bolt retainer ring directly against upper end of

RH. bearing cartridge. This will be at large end
of bearing bore. Wire cap screws.

11.

Bolt retainer to upper end of L.H. cartridge with

1/ 8 spacer between. Wire cap screws.
RH. bearing is secured endwise. The L.H. bearing
floats endwise within cartridge to allow for uneven expansion and contraction of eccentric shaft
and frame. Bearings are not preloaded.

12.

Apply a thin and uniform coating of micronized

graphite or light oil to bore of bearing and to
tapered portion of eccentric shaft.

13.

Mount shim pack on end of journal and assemble

bearing retainer plate.

14.

Force bearing on to shaft taper by tightening cap

screws as evenly as possible.
Bearing retainer plate must be clamped solidly against shims. It may be necessary to vary thickness of shim pack slightly
to keep internal running clearance within the recommended initial limits.
If excessive torque on retainer plate screws is required,
Item 8 under Eccentric and Gear Assembly.

15.

it may be necessary to resort to hydraulic assistance. See

Rotate bearing cartridges in frame so holes for bearing end plate cap screws line up. The lifting device shown in
Figures 3 and 4 will automatically align holes.
Bearing cartridge must enter bore in frame as bearing is put on shaft. Use a soft mallet on end of cartridge if necessary.

16.

Remove frame slot spreader jacks. Replace frame slot spacers. Be certain block
frame slot clamp studs, washer plates and nuts. Tighten nuts to approximately
Be sure ends of both bearing cartridges are flush with frame faces.

to frame keys are in place. Replace

500 foot pounds only at this time.

The end of L.H. bearing may not be flush with the end of its cartridge as this is the floating bearing. Plus or minus
1/1 6, or less, is satisfactory.
17.

Tighten nuts on frame slot clamp studs a minimum of 1/3 turn total (2 flats). This equals the torque shown in the
table on page 14.

It is important that these studs are tightened as recommended

to prevent stud and/or frame breakage.

18.

Bolt RH.

bearing end plate in place first.

19.

Bolt L.H. bearing end plate in place.

20,

Assemble the drive pinion on the shaft of the lube oil pump.

21.

Remove all tools and loose parts from the crankcase. Remove the device used to support the weight of the eccentric
assembly.

22.

Put the hood back in place. Be sure the gasket is in ood condition
grease on frame flange to help keep hood gasket in pl ace.

15-600

Page 9

and in proper location.

Bolt down securely. Use

23.

Do not forget to re lace or renew the crankcase oil. Now is a good time for an oil change and a new filter element
to protect the new b earings just installed.

CROSSHEAD

PINS

Procedure for Removal of Outer Crosshead Pins

1.

Cut wire and remove retainer plate to crosshead cap screws and use them as jack screws in tapped holes in plate to
pull pins. A little persuasion with a drift driven against the crosshead body and close to the large end of pin will help
loosen the pin.

Procedure for Removal of Center Crosshead Pin

1.

Remove outer crosshead next to lar e end of center crosshead pin to give room to remove pin from center crosshead.
Protect crosshead slide in frame with ith
ablock
of wood,

2.

Rotate pump until center crosshead is at end of its stroke toward fluid cylinder,

3.

Remove center crosshead pin as described above for the two outer pins.

PUSH RODS push rods can be removed from the crossheads by working through handhole plates in the sides of the
frame and also through the oil stop openings after the oil stop head assemblies have been removed.
Be careful not to damage the highly polished

surface on which oil seals bear.

Push rods are chrome plated and should be protected

CROSSHEADS Crossheads are one-piece

heads are made of ductile iron.

when the pump is painted. Paint will damage the oil stop head seals.

construction

and run on replaceable bronze slides bolted in the frame. Cross-

Procedure for Removal

1,

Remove

2.

Slide the crossheads through

surfaces from damage.

oil stop head- assemblies, crosshead pins and push rods as described above.
the oil stop openings in the frame and lift them clear. Be careful to protect the shoe

CROSSHEAD SLIDES The crosshead slides are cast of a tough bearing bronze. Top and bottom
and are bolted into the frame. Slides are also interchangeable end for end.

slides are interchangeable

The operating load is carried on the lower shoe and slide when pump is run in prescribed direction.
It is unlikely that upper slides will ever require replacement unless damaged by accident.
It is necessary to remove the jackshaft

in order to reach the cap screws which hold the upper crosshead slides to the frame.

Lower shoes may eventuaUy need to be replaced after long wear or if damaged. It is advisable to remove the crossheads
as described above in order to reach the countersunk head cap screws which secure the slides to the frame. The nuts are
on the outside and underneath the frame.
Use of shims between
instead of shimming.

the crosshead

slides and the frame is not recommended

as they may fret through. Use

Slides can be removed through oil stop head openings in frame, or through crosshead inspection

new slides

openings.

OIL STOP HEADS Oil stop heads keep the crankcase oil within the frame. They also keep mud and liner washing water
from entering the crankcase.
oil stop packing consists of two identical seals mounted in adaptors. They are 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 located.
The seal adaptors, with seals in them, can be slipped off and on the push rods by removing the claxnp holding piston rods
against the Push rods and separating the ISVOflanges. Do not use ascrewdriver
rod flanges. Turn the pump slightly.

or drift to separate the push rod and piston

It is essential that oil stop head seals be replaced at the first indication of leakage. Oil leakage will be indicated by oil collecting on top of the liner washing water in the reservoir. If rig water is used for washing and run to a waste area, it is difficult
to check by above method.

15-600

Page 10

If oil leakage is serious it will show up in a lower oil level in the crankcase. In this case oil must be added to crankcase as
required until new oil stop seals can be installed.
Leakage of mud and water into the crankcase will be indicated by a milky appearance of the crankcase oil. Mud will also
be seen below oil stop heads on inside of crankcase through crosshead inspection plate openings.
When mud is found in crankcase, oil should be changed. Drain and clean out crankcase before putting in the new oil. Replace seals in oil stop heads before running pump.
It is recommended

that oil stop head seals be changed every six months of operation,

15-600

Page 11

even though leakage is not evident.

SERVICE

INSTRUCTIONS

FLUID END

VALVE

CHAMBERS The PZ pump is equip ed with individual valve chambers (cylinders)

case hardened to provide the ultimate in strengt h .

forged from alloy steel and

Valve chambers are secured to frame with high tensile strength studs. It is important that nuts on these studs be checked
occasionally for tightness. A loose nut will eventually cause a stud to break under pulsating load. These connecting studs
extend through the stuffing box flanges. Stuffing boxes are clamped by means of above studs against the liner flanges
and serve to clamp liners tightly against valve chambers. A square rubber compound gasket seals end of liner against valve
chamber.
When replacing a valve chamber it is necessary to remove the discharge manifold. Also remove screws holding suction
manifold to the chamber being replaced. Loosen, but do not remove suction manifold screws in the other two chambers.
Suction manifold can be dropped enough to clear gaskets. These members are to be securely bolted to the new valve chamber
before it is finally tightened against frame connecting flange. Be sure manifold gaskets are in place.

LINER CLAMP AND LINERS when liner clamps are reinstalled or replaced, it is advisable to check cylinder to frame
stud nuts and tighten if necessary. Refer to table on page 14 showing proper tightening torques.
Nuts holding liner clamps in place should not be overtightened as distortion of the clamp and liuer bore may result. Recommended tightening torque is shown in table on page 14.
Change size of pistons and liners as volume and/or pressure requirements change. See rating chart on page 4.
Liners are replaced by removing the liner clamp. Liners should be cleaned and oiled after removal to protect against rusting
during storage, so they can be used again.
Pump liners are to be clean both inside and out when installed. Also clean the liner clamp bore and lightly oil all surfaces.
Use new gaskets when installing liners and be sure to clean all surfaces against which the gaskets fit. Liners or valve chambers
may be cut by leaking gaskets.

PISTONS Single-acting pistons are made up of special body fitted with a special piston insert develo ed for these singleacting pumps. Insert snaps into a groove in body. It is necessary to cut the piston insert off the piston body when replacement
is required.
Pistons, with piston rods, can be removed or installed through suction valve opening after valve upper guide is removed by
turning it 90 . Valve spring must also be removed.
It is recommended

that a piston and rod assembly be kept ready for replacement.

This is a practical time-saver.

PISTON ROD Piston rods are manufactured of high carbon steel. They are electrolytically plated to protect against
corrosion. 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 page 14.
Piston rod to piston fit is straight. Piston fits against flange on piston rod with an o ring gasket to prevent leakage. Removal
of piston is a simple operation since it is not driven up on a taper. Keep piston rod to push rod clamps tight at all times
to prevent damage to their connecting flanges and pilots. DO NOT use a screwdriver or cold chisel to separate the flanges.

PISTON WASHING SYSTEM The piston washing system is vital to the satisfactory performance and life of pistons and
liners. The complete system must be kept in good operating condition. Washing fluid should be maintained in good condition
and should be replaced when contaminated to the point where free circulation is impaired. This is of utmost importance
and should be impressed upon all operators of the pump.
Water su ply lines should be permanently attached to the openings provided in the circulating ump suction lines between
lating pump
and the tank. Water is then quickly available as a washing fluid or to flush out the lines by operating
the proper valves in the piping system.
The piston washing fluid may be varied according to conditions and operators preference. Water makes a suitable washing
fluid under most conditions. Good results can be obtained using water with one-half
anon of soluable oil per tank of
er some conditions, and can be used under severe freezing
conditions.
The more fluid circulated, the better; however, it should be related
culating pump to prevent splashing and being blown about.

by a valve in discharge line of the centrifugal cir-

MAINTENANCE OF VALVES In order to keep the pump in its best operation condition. it is necessarv to examine the
suction and discharge valves occasionally to see that excessive wear or cuttng by the slush or mud has not impaired their
efficiency. Any worn or damaged parts should be replaced.

15-600

Page 12

This is especially true with regard to the inserts. Standard inserts are made from urethane and are the part of the valve
which should be changed most frequently. They are much cheaper than, the valves and seats, and if inserts are renewed
as soon as they begin to fail, the more expensive steel parts will last much longer. Routine inspection of valves every two
or three days is recommended,
When removing a worn valve seat, use the Gardner-Denver puller powered with a hydraulic jack. Be careful to chain or
tie the jack down as it will jump violently when the valve seat lets go. If it becomes necessary to resort to the use of heat
or a cutting torch to remove a valve seat, the services of a man experienced in these operations is necessary.
Before putting new seats in the pum , the tapered bore in the valve seat deck of the cylinder must be thoroughly cleaned
with a wire brush. Wire brush shouldldbe used around
the bore rather than up and down. Wipe the bore clean and do not
use oil or grease. The bore must be clean and dry or seat may not seat properly.
Discharge valve seats should be instaUed with the rib or cross bar in line with the line of flow to discharge openin s. This
evenly divides the flow of li uid leaving the valve seat. If seats are installed with the rib across the line of flow, t he flow
is uneverdy divided and aturbulence is induced which results in high friction losses, and causes unequal wear on valve stems.
position of rib on suction valve is of less importance in this pump. Position of seats having three bars is also unimportant.
place the new seat in the bore. Use an old valve bumper or a block of hard wood and drive with a sledge to a snug initial
fit. The pressure load on the valve in operation will drive the seat home. Never reuse an old seat once it has been removed
from a cylinder, as it may not fit solidly in the valve deck.
Replace the upper valve
ide bushing if worn. Replace the valve spring if it is worn, corroded, distorted, or below normal
tension. Valves are provi ded with stainless steel springs for maximum operating life. A broken spring will 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.
insert to protect seat and bumper.

Be sure to replace a doubtful

It requires experience and judgment to determine if valve parts should be replaced or not. Valves are cheaper than downtime.
When installing valves put the gasket carefully in place in the valve chamber and install cover plate. Be sure gasket is not
twisted or extruded. Tighten valve cover lock securely by using a bar and hammer.
The life of the valves will be lengthened if the mud tanks are kept clean. In many cases foreign objects are caught under
the valves, thereby holding them open and causing rapid cutting of the seats and valves.

SUCTION

STRAINER

A suction strainer is recommended

for the suction line of every pump to protect

The PZ8, PZL and current PZ9 umps are not equipped with a suction strainer. A commercial
installed in the suction line ahe ad of the pump.

the valves.

strainer, however, may be

The earl PZ9

pumps were equi ped with a perforated metal strainer inside the suction manifold. This strainer can be removedfrom
the end opposite the suction line for inspection and cleaning. Strainer should be checked if the ump starts
to run rough, with violent discharge pulsations. One or more cylinders may have their suction obstructed by debris
d
in the
strainer.

15-600

Page 13

PZ9

PZ8
Min.
RECOMMENDED
(After Assembly)

RUNNING

CLEARANCES

Max.

PZL

Min.

Max.

Min.

Max.

(Inches)

Crosshead to Slide . . . . . . . . . . . . . . . . . . . . . .

.015

.034

.015

.034

.015

.034

Main Bearing..........,..

. . . . . . . . . . . .

.003

.006

.005

.008

.003

.008

. . . . . . . . . . . . . . . . . . . . . .

.002

.006

.002

.004

.002

.008

Crosshead Pin Bearing . . . . . . . . . . . . . . . . . . .

.001

.005

.002

.005

.001

.007

Connecting

Rod to Eccentric Bearing . . . . . . . . .

.002

.010

.002

.008

.002

.011

Oil Pump Pinion to Main Gear Backlash . . . . .

.010

.015

.010

.015

.010

.015

Jackshaft to Main Gear Backlash . . . . . . . . . .

.010

.020

.010

.020

.010

.020

.0006
Tight

.0028

.0007
Tight

.0031
Loose

.0014
Tight

.0025
Loose

.002
Tight

.0044
Tight

.002
Tight

,0044
Tight

.004
Tight

.000

Jackshaft Bearing

MANUFACTURING

FITS (Inches)

Jackshaft Bearing OD in Housing.

. . . . . . . . . . .

Jackshaft Bearing on Shaft . . . . . . . . . . . . . . . .

Loose

.0017

.0037

Tight

Tight

. . . . . . . . . . . . . .

.0035
Tight

.000

.004
Tight

.000

. . . . . . . . .

.002
Tight

.0055
Tight

.002
Tight

.006
Tight

.0022
Tight

.000

.0022
Tiiht

.000

.0005
Tight

.0025
Tight

.001

.0032

Tight

Tight

.0013
Tight

.0021
Loose

.0002
Loose

.0052
Loose

Connecting Rod to Eccentric Bearing:

ODin

Connecting Rod

ID on Eccentric,

,.

.006

.010

Tight

Tight

.001

.0038
Tight

Crosshead Pin Bearing

ODin

IDon

Connecting Rod

. . . . . . . . . . . . . .

----

Crosshead Pin . . . . . . . . . . . . . . . .

.0002
Loose

Main Bearing OD in Cartridge . . . . . . . . . . . . . .

Tapered Bore
Axial Takeup
.067 Average

Main Bearing on Shaft . . . . . . . . . . . . . . . . . . .

RECOMMENDED

.0036
Loose

Tight

Tapered Bore
Axial Takeup
.074 Average

Tapered Bore
Axial Takeup
,090 Average

TORQUES

185 Lb. Manon8Ft.

Wrench -PZ8
&PZ9)
Cylinder to Frame Stud Nut (
(Two 180 Lb. Menon5Ft.
Wrench -PZL).
Discharge Manifold Stud Nut(185Lb.
Connecting Rod Bolt (185 Lb. Man
Piston Rod Nut(185Lb.

Manon6

Frame Spacer Clamp Studs

Manon3-l/4

Ft. Wrench)

. . . . . . . . . . . . . . . . . . 1470 Ft. Lbs.

. . . . . . . . . . . . . . . . . . 1800 Ft. Lbs.

. . . . . . . . . . . . . . . . . . . . . . . . . .

600 Ft. Lbs.

3-1/4 Ft. Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 Ft. Lbs.

Ft. Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 Ft. Lbs.

(185 Lb. Man on 3-1/4 Ft. Wrench, or 1/3 Turn PZ8) . . . . . . . . . . . . .

(185 Lb. Man on 8-1/2 Ft. Wrench, or 1/3 Turn PZ9 & PZL) . . . . . . . .

Liner Clamp to Frame Stud Nut (185 Lb. Manon4Ft.

15-600

Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 14

600 Ft. Lbs.

1600 Ft. Lbs.
750 Ft. Lbs.

METHODS OF PREPARING PZ PUMPS FOR PREVENTION

OF DAMAGE DURING SHIPMENT Gardner-Denver
Company recommends
securing moving parts of large power pumps using roller bearings during shipment to prevent
damage to bearings by false Brinelling. Movement of bearing elements during transportation
may indent races and reduce
bearing life.
Method

of Preloading

All Bearings During Shipment

to Prevent

False Brinelling (Figure

6)

1.

Secure full thread stud to center (No, 2) piston rod. Tighten nut 50B8 against retainer plate (1 PZ1128 for Models
PZ8 & PZ9 and 203PZL168 for Model PZL) with a torque of 150 ft. lbs., pulling piston rod to cylinder end of stroke
as shown in Figure 6.

2.

Secure full thread studs to No. 1 and No. 3 piston rods in similar manner.

3.

Tighten inner nut 50B8 on cylinders No. 1 and No. 3 to 150 ft. lbs. torque, together and evenly.

4.

Lock nuts 50B8 by holding with wrench and tightening outer nut against inner.

To prepare pump for operation:

1.

Remove

above parts and store them for future use.

Method of Securing Eccentric Assembly

Against Sidewise Movement During Shipment (Figure 7)

,ECCENTRIC
MAIN BEARING

R 2PZI128
PZ8 & PZ9
B73080

24ZL8F
FIGURE

7.

1.

Remove pipe plugs from main bearing end plate and clamp plate each side of pump.

2.

Drive studs PZ1l 23 into clamp plates.

15-600

Page 15

3.

Slip grommets 60BQ3 onto studs PZ1 123 to keep out water and dirt.

4.

Clamp retainer bars (2PZ1128 for Models PZ8 & PZ9, and 204PZL168 for Model PZL) against bearing end plate with
nut 50B9. Tighten nut 50B9 on each side of pump to 150 ft. lbs. torque evenly. DO NOT FULLY TIGHTEN NUT
ON ONE SIDE FIRST.

5.

Lock nut 50B9 by holding it with wrench and tightening outer nut against inner.

To prepare pump for operation:

1.

Remove

studs PZ1 123, retainer plates and grommets

2.

Replace

1/ 2 pipe plugs

3.

Replace

3/4

4.

Store above parts for future use.

60BQ3.

in clamp plate.

pipe plugs in bearing plates.

15-600

Page 16

15-600

Page 17

15-600

Page 18

I
Oi

15-600

Page 19

15-600

Page20

&

For actdiionatinformation contact your local representative or

Garaner Denver Machinery Inc.. Customer service Dapar(mant,
1800 GardnerExpressway, Ouincy, Illinois 62301
Tefephom (800) 682-9866 FAX: (217) 224-7814

G**
4

P;sjj$$!%es
.

in all major cif,es.

@ **e
For parts irrforrnatim, mntact Gardner Denver,
Master Distribution Center, Marnpttis, TN
Tele~e:
(800) 246-4946 FAX: (901) 542-6159

Specificafiona
subject to change without notiie.
@yrigJW

1996 Gardner Denver Machinery Inc.

Ill

U.S.&