GARDNER DENVER
3–600

6th Edition
June, 1997

DUPLEX POWER PUMP

MODELS:

FXF – 5”
FXG – 6”
FXX – 8”
FXD – 10”
FXE – 10”

OPERATING AND
SERVICE MANUAL

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 MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER
PARTS AND SUPPORT SERVICES

Gardner Denver
and OPI
genuine pump parts are gency parts by direct access to the Gardner Denver
manufactured to original tolerances and designed for Machinery Inc. Master Distribution Center (MDC) in
optimum dependability. Design and material innova- Memphis, Tennessee.
tions are the result of years of experience with Your authorized distributor can support your Gardner
hundreds of different pump applications. Reliability in Denver and OPI pump needs with these services:
materials and quality assurance are incorporated in our
genuine replacement parts. 1. Trained parts specialists to assist you in select-
ing the correct replacement parts.
Your authorized Gardner Denver and OPI distribu- 2. Repair and maintenance kits designed with the
tor offers all the backup you’ll need. A worldwide necessary parts to simplify servicing your pump.
network of authorized distributors provides the finest
product support in the pump industry. Authorized distributor service technicians are factory–
trained and skilled in pump maintenance and repair.
Your local authorized distributor maintains a large in- They are ready to respond and assist you by providing
ventory of genuine parts and he is backed up for emer- fast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver and OPI distributor refer to the yellow pages
of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: (217) 222–5400
Phone: (901) 363–6100 Fax: (217) 224–7814
Fax: (901) 363–1095

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL and SE- per unit, quantity is indicated in parenthesis. SPECIFY
RIAL NUMBER (see nameplate on unit). The Serial EXACTLY THE NUMBER OF PARTS REQUIRED.
Number is also stamped on top of the cylinder end of
the frame (cradle area). DO NOT ORDER BY SETS OR GROUPS.

All orders for Parts should be placed with the near- To determine the Right Hand and Left Hand side of a
est authorized distributor. pump, stand at the power end and look toward the fluid
end. Right Hand and Left Hand are indicated in paren-
Where NOT specified, quantity of parts required per thesis following the part name, i.e. (RH) & (LH), when
pump or unit is one (1); where more than one is required appropriate.

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 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 opera-
tion, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and
minimum downtime.

Danger is used to indicate the presence of a hazard which will cause severe personal
injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe person-
al injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.

Notice is used to notify people of installation, operation or maintenance information

which is important but not hazard–related.

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 TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Repair Parts Ordering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

List of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Danger Notices, Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation and Operating Instructions, Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Routine Maintenance & Service Instructions, Section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Dimensions & Running Clearances, Section 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TroubleShooting, Section 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

List of Illustrations

Figure 1 Crankcase Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 2 Lubrication Fill Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 3 Packing Type Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 4 Cup Type Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 5 Piston Textures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 6 Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 7 Rotation of Eccentric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 8 Jackshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 9 Eccentric and Main Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 10 Crosshead Pin Removal – FXX, FXD & FXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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 INDEX

Baffle, Fluid Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . 9 Fluid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Boiler Feed or Low Pressure Water Service . . . . . . . 8 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Clean Oil or Petroleum Products Services . . . . . . . . 9 Frame Oil Stop Head Packing . . . . . . . . . . . . . . . . . . . 9
Covers and Guards, Danger Notice . . . . . . . . . . . . . . 2 FXE Main Gear and Eccentric . . . . . . . . . . . . . . . . . . 13
Crosshead Pin Removal – FXF & FXG Pumps . . . 12 Hammer Lug Fasteners, Danger Notice . . . . . . . . . . 1
Crosshead Pin Removal – FXX, FXD & FXG . . . . . 13 High Pressure Liquid Jetting, Blasting and Cleaning,
Danger Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Daily Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Pressure Pistons for Abrasive Service . . . . . . . 9
DANGER NOTICES, SECTION 1 . . . . . . . . . . . . . . . 1
High Pressure Special Fluid Service . . . . . . . . . . . . . 8
Danger Notices
High Temperature Service . . . . . . . . . . . . . . . . . . . . . . 9
Covers and Guards . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Puller, Danger Notice . . . . . . . . . . . . . . . . . 2
Equipment Moving and Lifting . . . . . . . . . . . . . . . 2 Inspection, Occasional . . . . . . . . . . . . . . . . . . . . . . . . 12
Flammable, Hot, Cold or Corrosive Fluid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION AND OPERATING INSTRUC-
Hammer Lug Fasteners . . . . . . . . . . . . . . . . . . . . 1 TIONS, SECTION 2 . . . . . . . . . . . . . . . . . . . . . . . . 7
High Pressure Liquid Jetting, Blasting and Installation of Jackshaft Oil Seals . . . . . . . . . . . . . . . 12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Jackshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lifting and Moving Equipment, Danger Notice . . . . . 2
Pressurized Pump Systems . . . . . . . . . . . . . . . . . 3 Liners, Fluid Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve Seat Pulling . . . . . . . . . . . . . . . . . . . . . . . . . 2 Low Pressure Water or Boiler Feed Service . . . . . . . 8
Wedge Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Data for FXD, FXE and FXX Power Pumps . . . . . . 16 Main Bearings, Install . . . . . . . . . . . . . . . . . . . . . . . . . 13
Data for FXG and FXF Power Pumps . . . . . . . . . . . 17 Moving and Lifting Equipment, Danger Notice . . . . . 2
Dimensions Occasional Inspection . . . . . . . . . . . . . . . . . . . . . . . . 12

Fluid End Piston Rod Stuffing Box . . . . . . . . . . 15 Operating Speeds and Pressures . . . . . . . . . . . . . . 14
Ordering Instructions, Repair Parts . . . . . . . . . . . . . . i
Power End Oil Stop Head . . . . . . . . . . . . . . . . . . 15
Packing
DIMENSIONS & RUNNING CLEARANCES,
SECTION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fluid Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . 9
Equipment Moving and Lifting, Danger Notice . . . . . 2 Fluid Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flammable, Hot, Cold or Corrosive Fluid Pumping, Frame Oil Stop Head . . . . . . . . . . . . . . . . . . . . . . . 9
Danger Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Packing and Fluid Pistons . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Cylinder Liner Packing . . . . . . . . . . . . . . . . . . . . 9 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fluid Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fluid Inlet or Suction . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid End Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Suction or Fluid Inlet . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid End Piston Rod Stuffing Box Dimensions . . . 15 Piston, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fluid Inlet or Suction Piping . . . . . . . . . . . . . . . . . . . . . 7 Piston Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fluid Piston Rod Baffle . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power End Oil Stop Head Dimensions . . . . . . . . . . 15
Fluid Piston Rod Packing . . . . . . . . . . . . . . . . . . . . . . . 9 Pressures and Operating Speeds . . . . . . . . . . . . . . 14
Fluid Pistons and Packing . . . . . . . . . . . . . . . . . . . . . . 8 Pressurized Pump Systems, Danger Notice . . . . . . 3

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 Recommended Running Clearances High Pressure Special Fluid . . . . . . . . . . . . . . . . . 8
FXD, FXE and FXX Power Pumps . . . . . . . . . . 16 High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 9
FXG and FXF Power Pumps . . . . . . . . . . . . . . . 17 Low Pressure Water . . . . . . . . . . . . . . . . . . . . . . . 8
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Specifications, Torque . . . . . . . . . . . . . . . . . . . . . . . . 18
Repair Parts, Ordering Instructions . . . . . . . . . . . . . . i Starting a New Pump . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair Parts Maintenance . . . . . . . . . . . . . . . . . . . . . 13 Storage of Pump, Special Care . . . . . . . . . . . . . . . . 14
Repair Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . 13 Suction or Fluid Inlet Piping . . . . . . . . . . . . . . . . . . . . . 7
Rods, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 18
ROUTINE MAINTENANCE & SERVICE TROUBLESHOOTING, SECTION 5 . . . . . . . . . . . . 19
INSTRUCTIONS, SECTION 3 . . . . . . . . . . . . . . 12 Valve, Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service Valve Seat Pulling, Danger Notice . . . . . . . . . . . . . . . 2
Abrasive, High Pressure Pistons . . . . . . . . . . . . . 9 Valves, Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boiler Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
Clean Oil or Petroleum Products . . . . . . . . . . . . . 9 Wedge Puller, Danger Notice . . . . . . . . . . . . . . . . . . . 2

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 SECTION 1
DANGER NOTICES

personnel to refresh their memories in safe procedures

and practices.
Keep in mind that full operator attention and alertness
Read and understand the following DANGER NO- are required when operating high pressure pumping
TICES before moving or operating the pump or any equipment. Operators should not begin or continue op-
pump package unit equipment. erations when tired, distracted or under the influence of
Reciprocating pumps are machines capable of produc- alcohol or any type of prescription or nonprescription
ing high fluid pressures and flow rates and are de- drugs.
signed to be used with proper care and caution by The timely replacement of expendable parts and any
trained, experienced operators. TO AVOID PER- other worn or damaged parts can prevent equipment
SONAL INJURY, DEATH AND/OR EQUIPMENT damage and possible injury. The original parts used in
DAMAGE, READ AND THOROUGHLY UNDER- Gardner Denver pumps are designed and tested to ex-
STAND THE FOLLOWING DANGER NOTICES acting standards to provide high quality performance
PLUS THE ENTIRE OPERATING AND SERVICE and durability. Your best insurance in maintaining
MANUAL BEFORE ATTEMPTING TO MOVE OR these characteristics is to use genuine Gardner Denver
OPERATE THE PUMP. Contact a Gardner Denver replacement parts.
Machinery service representative if you are unable to
comply with any of the danger notices or procedures A broad range of danger notices are covered on these
described in these documents. pages, however, they cannot substitute for training, ex-
perience and common sense in the safe operation of
Closely examine the data plate upon pump delivery to high pressure pumping equipment.
become thoroughly familiar with the operating limits for
HAMMER LUG FASTENERS
this pump model. The pump must never be operated
at speeds, pressures or horsepower exceeding the
maximum values shown on the data plate or at
speeds below the minimum shown. Failure to ob-
serve the operating limits shown on the data plate On pumps or pump package units equipped with ham-
could result in personal injury, death, and/or mer lug connectors and/or hammer lug valve covers
equipment damage and will void the warranty. Al- the following precautions must be observed to avoid
terations to the pump, or application of the pump out- personal injury, death and/or equipment damage due
side the data plate limits, must not be made without to contact with the hammer, hammer bar, broken parts
Gardner Denver Machinery written approval together from the hammer, hammer bar or lugs or other objects
with a new data plate, as dangerous operating condi- propelled by hammer blows. When tightening or loos-
tions could result. ening hammer lug connectors and valve covers, opera-
tors or maintenance personnel should:
THE DANGER NOTICE AND DATA PLATES PRO- S Inspect the hammer, hammer lugs and hammer
VIDED ON THE EQUIPMENT MUST NOT BE RE- bar, if one is used, to insure they are all in good
MOVED, PAINTED OVER, HIDDEN OR DEFACED. condition. Replace any of these parts which are
They must be replaced if they become damaged or un- cracked, damaged or badly worn.
readable. Provisions should be made to have the fol-
lowing written danger notices plus the pump operating S Wear safety shoes and goggles.
and service manual readily available to operators and
S Alert other personnel to move away from the
maintenance personnel. In addition, copies of all pump
area.
system accessory component (e.g. pressure relief
valve, pulsation dampener, suction stabilizer, engine, S Check to insure they have safe footing.
electric motor, etc.) operating and service manuals
S Fully engage the hammer bar, if one is used, to
should be readily available for operator and mainte-
prevent it from disengaging violently from the
nance personnel use. Read and follow all the precau-
cover as a blow is struck.
tions and instructions contained in these manuals. If
any of these documents are lost or become illegible S Wipe their hands and the hammer handle and
they must be replaced immediately. The danger no- maintain a firm grip on the handle to avoid losing
tices plus the operating and service manuals should be control of the hammer while swinging and strik-
reread periodically by both operators and maintenance ing.

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 S Carefully swing the hammer to avoid striking Covers and guards are intended to not only protect
themselves, another person and objects other against personal injury or death, but to also protect the
than the targeted lugs or hammer bar. equipment from damage from foreign objects.
S Avoid swinging the hammer above shoulder EQUIPMENT MOVING AND LIFTING
height.
VALVE SEAT PULLING
Heavy equipment including pumps, pump package
units and components should only be moved or lifted
by trained, experienced operators, who are physically
The following precautions must be observed by opera-
and mentally prepared to devote full attention and alert-
tors and maintenance personnel to avoid personal inju-
ness to the moving and lifting operations. An operator
ry, death and/or equipment damage from contact with
should be fully aware of the use, capabilities, and
the puller, hammer, wedge or broken parts from these
condition of both the equipment being moved and the
components when using either a hydraulic or wedge
equipment being used to move it.
valve seat puller:
Hydraulic Puller
S Wear safety shoes and goggles.
S Chain or tie the jack down as it will jump violently Failure to follow safe and proper
when the valve seat disengages from the valve pump, pump package or component
deck. lifting or moving procedures can lead
S Check to insure the pressure applied by the hy- to personal injury, death and/or
draulic pump does not exceed the hydraulic equipment damage from shifting, fal-
ram maximum pressure rating.
ling or other unexpected or uncon-
Wedge Puller trolled equipment movements.
S Grind off any mushroomed material from the
wedge before use.
Make sure the hoist, lift truck, ropes, slings, spreader,
S Follow the danger notices listed above in the or other lifting equipment you are using is in good condi-
hammer lug section, but substitute the term tion and has a rated lifting capacity equal to or greater
wedge for hammer lug and hammer bar. than the weight being lifted. Lifting devices must be
checked frequently for condition and continued confor-
mance to rated load capacity. They should then be
COVERS AND GUARDS
tagged with the inspected capacity together with the
date of inspection.
Fully assembled pumps and pump package units are
heavy and should only be moved using the specified
lifting lugs or attachments. Many individual compo-
All pump covers must be securely nents have lifting eyes or lugs which must not be
fastened in proper position at all used to lift assemblies, as they are designed to
bear the weight of the component only. Before lift-
times when the pump is operating to
ing the individual component check to insure the lifting
avoid personal injury or death from attachment is firmly secured to the component with un-
moving parts. In addition, all moving damaged, properly torqued fasteners, sound welds, or
parts on the entire pump package, in- other secure attachments. Examine the lifting eyes,
cluding but not limited to engine or lugs, slots, holes or other projections to insure they are
not cracked, otherwise damaged or badly worn. The
motors, drive shafts, belts, chains,
repair of existing or addition of new welded lifting eyes,
pulleys, gears, etc., must be equipped lugs or other projections should only be performed by
with guards or covers, which must experienced, qualified welders.
also be securely fastened in proper Package units should be lifted with spreaders con-
position at all times when the equip- nected to the lifting attachments normally built into the
ment is operating. package unit support skid. Packages too large to lift ful-
ly assembled should be separated into smaller loads.

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 For these smaller loads the lifting devices should be The relief valve should be placed in the flowing dis-
fastened to the lifting attachments normally built into charge line and not at the opposite end of the discharge
the individual motor, engine, pump or transmission/ manifold in a dead end connection. The dead end may
torque converter, or their separate support skids. become clogged with solid material carried in the fluid,
which could prevent proper relief valve operation.
When lifting subassembled components, for example
a suction stabilizer attached to suction piping or a dis-
charge pulsation dampener attached to a strainer cross
and piping, use special lifting slings designed to safely
support the combined weight of the components.
Never place a shut–off valve or any
If a crane or hoist is being used to lift large components other component between the pump
or assemblies, one or more persons should assist the discharge connection and the pres-
operator from the ground with guide lines attached to
the equipment being moved to properly position it and
sure relief valve.
prevent uncontrolled movement.
When you start to lift a pump, package unit, subassem- Make sure the pressure relief valve is installed so any
blies or individual components and you observe the pressurized relief discharge from the valve is directed
equipment is tilting, or appears unbalanced, lower the away from possible contact with people or equipment.
equipment and adjust the lifting device to eliminate The relief valve must be set to relieve at a pressure
these improper lifting conditions before proceeding to equal to or below the maximum pressure values shown
move the equipment. on the pump data plate. However, if a component is
used in the discharge system with a lower rated pres-
It is poor practice and dangerous to allow the equip- sure capability than that listed on the pump data plate,
ment to pass over or close to your body or limbs. Be the pressure relief valve must be set to relieve at a pres-
prepared to move quickly out of danger if equipment sure equal to or below the rated capability of the lowest
starts to fall, slip or move unexpectedly toward you. rated component.
PRESSURIZED PUMP SYSTEMS Before starting the pump every time, check to in-
sure:
S The pressure relief valve is in good operating
condition and has been set to the proper relief
Fluids under high pressure can pos- pressure.
sess sufficient energy to cause per- S Any pipe line used to direct pressurized relief
sonal injury, death and/or equipment flow to another location, such as a collecting
tank, is not blocked.
damage either through direct contact
with escaping fluid streams or by con- S The discharge system is not blocked and all the
tact with loose objects the pressur- discharge line valves are open.
ized fluid propels. Check all fluid end discharge system components
including pipe, connections, elbows, threads, fas-
teners, hoses, etc., at least once every six months
Operating a pump against a blocked or restricted dis- to confirm their structural adequacy. With time,
charge line can produce excessive pressures in the en- wear, corrosion and fatigue can reduce the strength of
tire discharge system, which can damage or burst dis- all components. Magnetic iron and steel components
charge system components. should be checked with magnetic particle or dye pene-
trant crack detection equipment. Nonmagnetic materi-
als should be checked for cracks with dye penetrants.
All metallic components should also be visually
checked during these inspections for signs of corro-
Never operate a pump without a prop- sion. If a component shows evidence of cracking or
loss of material due to corrosion it must be replaced
erly sized pressure relief valve lo-
with a new part.
cated in the flowing discharge line im-
mediately adjacent to the pump dis- Continually monitor suction and discharge hose as-
semblies when the pump is operating for leakage, kink-
charge connection. ing, abrasion, corrosion or any other signs of wear or
damage.

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 Worn or damaged hose assemblies should be re- controls are clearly tagged with warnings not to start
placed immediately. At least every six months ex- the pump while repair work is in process.
amine hose assemblies internally for cut or bulged Whenever the pump is operating, continually monitor
tube, obstructions and cleanliness. For segment style the entire suction, discharge and pump lubricating sys-
fittings, be sure that the hose butts up against the nipple tems for leaks. Thoroughly investigate the cause for
shoulder, the band and retaining ring are properly set leakage and do not operate the pump until the cause
and tight and the segments are properly spaced. of the leak has been corrected. Replace any parts
Check for proper gap between nut and socket or hex which are found to be damaged or defective. When a
and socket. Nuts should swivel freely. Check the lay- gasketed joint is disassembled for any reason, discard
line of the hose to be sure that the assembly is not the used gasket and replace it with a new, genuine Gar-
twisted. Cap the ends of the hose with plastic covers dner Denver gasket before reassembling the joint.
to keep them clean until they are tested or reinstalled
on the pump unit. Following this visual examination, Due to the high working pressures contained by the
the hose assembly should be hydrostatically tested, on fluid cylinder, discharge manifold and discharge piping,
test stands having adequate guards to protect the oper- welding on these components is not recommended. If
ator, per the hose manufacturer’s proof test procedure. welding on the discharge system cannot be avoided,
only experienced, qualified welders should be used. In
Fluid end component inspections should be per- addition, the welded part should be hydrostatically
formed more frequently than every six months if proof tested in the shop with water or hydraulic fluid to
pressures above 2500 psi are used in the dis- one and one half times maximum discharge system
charge system or if corrosive, flammable or hot working pressure, with no observable fluid leakage, be-
(over 110_ F) fluids are being pumped. fore the part is reinstalled in the pump system.
Proper stuffing box packing selection is important for In summary, high pressure fluid streams can possess
safe pump operation. Contact a Gardner Denver Ma- sufficient energy to cause personal injury, death and/or
chinery service representative for assistance in select- equipment damage. These results can occur either
ing the proper packing before beginning operation. through direct contact with the fluid stream or by con-
tact with loose objects the fluid stream has propelled,
Before starting the pump for the first time and periodi- if the pump system is improperly used, or if the fluid is
cally thereafter check the pump, suction and discharge misdirected, or allowed to escape from defective or im-
system fastener torques versus the values listed in the properly maintained equipment.
Operating and Service Manual tables to insure proper
tightness. Over and under torquing can damage
FLAMMABLE, HOT, COLD OR CORROSIVE FLUID
threaded pipes, connections and fasteners, which may
PUMPING
lead to component damage and/or failure. Replace all
components found to be damaged or defective. On
pumps equipped with stuffing boxes, the gland must be
engaged by at least three (3) threads to hold the dis-
charge pressure of the pump.
Extreme caution must be exercised
by trained and experienced operators
when flammable, hot, cold or corro-
sive fluids are being pumped, in order
Do not attempt to service, repair, ad-
to avoid personal injury, death and/or
just the plunger packing or otherwise
equipment damage due to explosion,
work on the pump while the unit is op-
fire, burn, extreme cold or chemical
erating. Shut off the pump drive mo-
attack.
tor or engine and relieve the fluid
pressure in the pump suction and dis-
charge systems before any work or Never operate a pump which is pumping hydrocarbons
or other flammable, hot, cold, or corrosive fluids when
investigation is performed on the any part of the pump, suction system or discharge sys-
pump or pump systems. tem is leaking. Stop the pump immediately if any leak-
age, other than a few drops per minute of packing
weepage, is observed. Keep all flame, sparks, or hot
Block the crankshaft from turning and make certain that objects away from any part of the pump, suction sys-
all pump drive motor or engine start switches or starter tem, or discharge system. Shield the pump, suction

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 system and discharge system to prevent any flam- HIGH PRESSURE LIQUID JETTING, BLASTING
mable, hot, cold or corrosive fluid leakage from dripping AND CLEANING
or spraying on any components, flame, sparks, hot ob-
jects or people. Inspect the plungers, packing, gaskets
and seals for fluid leakage frequently and replace all
worn or leaking parts.
Extreme caution must be exercised if
Selection of the proper gaskets, seals and stuffing box any type of wand, gun, nozzle or any
packing is even more critical when flammable, hot, cold other pressure and flow directing de-
or corrosive fluids are being pumped than when other, vice is attached to the pump dis-
inherently less dangerous fluids are used. Contact a
charge system for use in jetting,
Gardner Denver Machinery service representative for
assistance in selecting the proper gaskets, seals and blasting, cleaning, etc. This type of
packing before beginning operation. equipment must be used with utmost
care by trained, experienced opera-
Since some packing weepage into the cradle area is in- tors. High pressure fluid streams can
evitable, the drain at the bottom of the cradle must be either by direct contact or by propel-
connected to a drain line which conducts the fluid leak- ling loose objects, cause serious per-
age to a collection container located in a protected
area. The entire drain system and container must be
sonal injury or death to the operators
constructed of materials resistant to attack from the and/or other persons.
pumped fluid or from explosion or fire of the pumped
fluid. Heavy duty cradle covers must be securely Pressure or flow directing devices often receive pres-
fastened in the proper position on the pump at all surized flow through flexible hoses, which can burst if
times when the pump is operating. If the pumped they are kinked, cut, abraded or are otherwise worn,
fluid releases harmful, explosive or flammable va- damaged or pressured above their rated capacity. Pro-
pors the covers must be vented to conduct the tect the hose and connections from damage by people,
fumes away from the pump unit to a nonhazardous objects and vehicles. A broken, cut or otherwise burst
area. hose can release pressurized fluid which may cause
personal injury, death and/or equipment damage.
Before beginning pumping operations or starting the High pressure fluid from hand held or hand directed
pump power source (whether an engine or electric mo- pressure and flow directing devices may overpower an
tor) check the atmosphere all around the pumping site operator’s ability to control or direct the device, which
for the presence of flammable or explosive vapors. Do could lead to personal injury, death and/or equipment
not begin operation and stop ongoing operation if flam- damage. The operator must brace against the back-
mable or explosive vapors are detected. Hot surfaces, ward thrust of a hand held device. In addition, a safety
sparks, electric current or engine exhaust could ignite harness or safety net must be used when working in an
flammable or explosive vapors. Each engine used as area where the operator could be injured in a fall. Stand
a power source on pumping units where flammable or to the side of any tubing or container being sprayed to
explosive vapors could form should be equipped with avoid back spray and never operate a hand held device
an air inlet shut–off. If flammable or explosive vapors above shoulder level.
are present in the pumping site atmosphere, an engine
could continue to run on these vapors even after the en- Never direct the pressurized fluid stream at yourself or
gine fuel line is shut–off if an air inlet shut–off is not any other person, control valves, the pump, pump
used. drive, suction or discharge systems. The pressurized
stream can cause serious personal injury or death and
can also change valve or control settings which could
In addition, on pumping units used where flammable or dangerously increase the delivery pressure to the pres-
explosive vapors could form, all electric motors used as sure and flow directing device.
power sources must be of explosion proof construction
and all electrical components and wiring must meet the When operating a pressure and flow directing device,
current National Electrical Code for explosive atmosp- use only equipment which automatically shuts off flow
heres. when an operator releases hand or foot pressure on the
pressurized flow trigger control to prevent injury if the
operator is overpowered or becomes disabled.
These precautions must be taken to avoid possible per-
sonal injury, death and/or equipment damage from ex- Check to insure this automatic shut–off equipment is
plosion, fire or burns. operating properly before every use and never circum-

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 vent the automatic shut–off for any reason or by any guns, hoses, connections or any other pressurized
means when operating the equipment. system components.
When operating any type of high pressure liquid jetting, All pressure containing devices including wands,
blasting or cleaning devices the operators must always nozzles, guns, connections, etc., plus all automatic
wear protective clothing including, but not limited to, a shut–off, pressure and control equipment should be
hard hat with full face visor, heavy duty rain coat and treated with care. Protect them from damage by
pants, boots with nonskid sole and safety toe, rubber people, objects and vehicles. Never lay them in dirt,
gloves with rough grip surface and ear noise protection. mud, ice or other loose material which could plug the
Full operator attention and alertness are required when fluid opening or interfere with their operation. Never
operating this equipment to avoid personal injury, death use the wand, nozzle, gun, etc. to pry loose material off
and/or equipment damage. The operators should take items being cleaned.
frequent rest breaks and cease operations when they Before starting operation in a cold environment, check
become tired or distracted. to make sure there is no ice in the fluid system and re-
Before the equipment is started, the work area must be peat this inspection each time before operation is re-
inspected and properly prepared to avoid personal inju- started.
ry, death and/or damage to equipment. Make sure the Before purchasing wands, nozzles, guns, connections,
work area is checked for hazardous fumes, has ade- and hose, etc., manufacturers of these components
quate ventilation for engine exhaust and sufficient should be contacted for detailed information on the de-
drainage for released fluid. Check the work area for sign and safety features incorporated in their products.
electrical equipment, connections, outlets, fixtures, or After careful study of various manufacturers products,
lines. If any are present they must be made water tight we recommend that only those wands, nozzles, guns,
and the electrical power to these devices must be shut connections and hose, etc., be considered for pur-
off to avoid electrical shocks from fluid contact. The chase that you judge to offer the highest quality of de-
work area should be clearly marked and roped off to sign, construction and safety, since these components
keep unauthorized people and vehicles from entering. are among the most critical to the safe operation of high
Remove all loose parts, tools and equipment from the pressure liquid jetting, blasting and cleaning equip-
work area before beginning operation. ment.
All pressure containing devices including wands, After you have selected and purchased these compo-
nozzles, guns, hoses, connections, etc., should be reg- nents, follow the manufacturer’s instructions complete-
ularly checked for condition. These components ly in their use.
should all be tagged with their tested pressure capabili-
ties together with the date testing was performed. Al- In summary, high pressure jetting, blasting and
ways be aware of the pressure level in the system cleaning are inherently dangerous, as the pressur-
and never connect any equipment to the system es and flow rates needed to remove scale, clean,
which has a rated or tested pressure capability be- etc. are sufficient to cause personal injury, death
low the system operating pressure. The equipment and/or equipment damage resulting from, but not
must be shut down and the system pressure released limited to, any of the conditions described in the
before changing or disconnecting wands, nozzles, above Danger Notices.

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 SECTION 2
INSTALLATION & OPERATING INSTRUCTIONS

FOR GARDNER DENVER FXF, FXG, FXX, FXD and FXE DUPLEX POWER PUMPS

INSTALLATION – The pump should be installed as Fluid Inlet or Suction Piping – Inlet piping should be
close to the fluid supply as possible. Whenever pos- as direct and short as possible and should be laid out
sible, ample space should be provided around the so that air pockets are eliminated. The inlet pipe must
pump to facilitate inspection and adjustment with par- never be smaller than the pump inlet and lines longer
ticular attention to the space required for removal and than 20 feet (6 meters) (including friction) must never
installation of piston rods, liners and jackshafts. be exceeded. To protect the pump from foreign matter,
an inlet strainer should be installed with a net area of
Pump should be properly leveled and securely fas-
four times the inlet pipe.
tened to whatever type of foundation is provided.
The drive must be accurately aligned. Fluid Discharge Piping – It is advisable to use an am-
ple size discharge line to prevent excessive friction.
PIPING The use of an air chamber is recommended and ample
size chambers are available for all pumps.

RELIEF VALVE – Pump must be protected from ex-

cess pressure by a discharge pressure relief valve. The
All piping must be supported inde- valve must be installed near the pump, preferably in the
pendently of the pump to insure that opening provided for it in the discharge manifold on
no strain is imposed on the pump by models where applicable. Never install a shutoff valve
in the line between the relief valve and pump cylinder.
misalignment or improperly fitted
The relief valve should be set to operate at approxi-
pipe. mately 1–1/4 times the discharge pressure, but must
not exceed system equipment tolerances.

CRANKCASE OIL REQUIREMENTS

Crankcase
API–GL5 Ambient Operating Oil Minimum Startup
Oil Grade Temperature Temperature * Oil Temperature
75W–90 –20_ F to 90_ F 60_ to 170_ F 20_ F
(–29_ C to 32_ C) (16_ C to 77_ C) (–7_ C)
80W–140 10 F to 120 F 90_ F to 200_ F 50_ F
(–12_ C to 49_ C) (32_ C to 93_ C) (10_ C)
80 –10_ F to 60_ F 70_ F to 140_ F 30_ F
(–23_ C to 16_ C) (21_ C to 60_ C) (–1_ C)
90 20_ F to 100_ F 100_ F to 180_ F 60_ F
(–7_ C to 38_ C) (38_ C to 82_ C) (16_ C)
140 50_ F to 120_ F 130_ F to 200_ F 80_ F
(10_ C to 49_ C) (54_ C to 93_ C) (27_ C)
* An 80_ F (27_ C) crankcase oil temperature rise over ambient air temperature is typical
for the pumps covered by this manual when operating at or near rated horsepower.

FIGURE 1 – CRANKCASE OIL REQUIREMENTS

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 Improper use or maintenance of relief
valves can cause excessive pressure
which may result in property damage
and/or serious personal injury or
death.

When the pump is equipped with Shear Type Relief

Valve, use only one Shear Pin of the size shown on the
setting plate. The use of a nail or any shear device other
than Vendor Shear Pin may be extremely hazardous.
Do not hammer on shear bar or stem or shear bar slot.
LUBRICATION – Recommended crankcase oils are
FIGURE 3 – PACKING TYPE PISTON
as shown in FIGURE 1, page 7.
Oil viscosity must not exceed 7000 SSU at startup and
must be between 1500 SSU and 130 SSU while operat- grease NLGI Grade No. 2 should be supplied to these
ing, regardless of the oil temperature or grade used. A with discretion. Roller bearings WILL HEAT IF TOO
crankcase heater and/or an oil heat exchanger may be MUCH GREASE is used, especially if bearing is com-
needed to meet these requirements. pletely filled with grease.
Failure to follow these lubrication requirements will void FLUID PISTONS AND PACKING – Four general types
the warranty. of fluid pistons and packings are used, depending upon
operating conditions or requirements. The pumps are
The approximate quantities of lubricant required to packed at the factory complete.
properly fill the crankcases of each size pump are as
follows: Low Pressure Water or Boiler Feed Service – For
low pressure water or boiler feed service, use iron or
bronze follower type pistons with fibrous duck and rub-
Stroke ber rings having regular or rock hard cure. Regular cure
Power U.S Imperial rings are recommended for fluids with temperatures of
Inches mm End Gallons Gallons Liters 180_ F (82.2_ C) or lower. Rock hard rings should al-
ways be used for fluids with higher temperatures to
5 127 FXF 3 2–1/2 11–1/2
250_ F (121.1_ C) maximum. Ring lateral clearance
6 152.4 FXG 4–1/2 3–3/4 17 between the follower and piston body flange is deter-
mined by the amount of packing. Clearance should be
8 203.2 FXX 12 10 46 1/16” (1.5875 mm) for 3” (76.2 mm) width packing and
10 254 FXD 14 11–3/4 53 under, and 1/8” (3.1 75 mm) for width beyond 3” (76.2
mm). The rings should be installed with the end step–
10 254 FXE 14 11–3/4 53 cut joint gap of 1/32” (.7937 mm) for 3” (76.2 mm) diam-
eter and under, 1/16” (1.5875 mm) for 3” (76.2 mm) to
7–1/2” (190.5 mm), and 1/8” (3.175 mm) beyond 7–1/2”
FIGURE 2 – LUBRICATION FILL RATE (190.5 mm) diameter. All regular cure and rock hard
piston packing should be soaked at least eight hours in
warm water before installing.
Oil must be added as required to maintain the level to
High Pressure Special Fluid Service – For high pres-
the top of the street elbow in the end of the frame. Time
sure water and mildly abrasive fluids, the cup type pis-
between oil changes depends upon local conditions.
tons are recommended. Pistons are available in
However, if crankcase is kept closed, it should not be
bronze, steel, iron, monel and stainless steel. Fluids
necessary to change oil any more than each 1000
such as acids and alkalis require special cup composi-
working hours.
tions and should be referred to factory for information.
Jackshaft and eccentric shaft roller bearings are sealed
To assemble the piston to the rod, proceed as follows:
off from the crankcase lubricant and are provided with
pressure gun grease fittings. A reliable multipurpose 1. Mount the hub to the taper.

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 Temperature Pressure Texture

–20_F to 212_F 0 to 125 PSI Soft

(–28.9_C to 100_C) (0 to 8.79 kg/cm2)

–20_F to 300_F 100 to 500 PSI Medium

(–28.9_C to 148.9_C) (7.03 to 35.15 kg/cm)

30_F to 300_F 500 to 1000 PSI Hard

(–1.1_C to 148.9_C) (35.15 to 50.31 kg/cm)

FIGURE 4 – CUP TYPE PISTON FIGURE 5 – PISTON TEXTURES

2. Fit cup snugly to the hub. Maximum rated service temperature is 250_ F.
3. Mount the spacing plate. Rod packings should always be installed in a clean
4. Mount the outer cup. stuffing box. Each ring should be firmly seated by tamp-
ing as it is applied. When box is full, gland nuts should
5. Mount the follower plate and tighten the nut and be tightened with a wrench just enough to seat the
locknut securely. packing properly; then slacken off and tighten nuts by
hand, locking the gland with a final quarter turn with a
For the texture of the cups, see FIGURE 5. wrench. DO NOT TIGHTEN GLANDS TOO TIGHT.
Clean Oil or Petroleum Products Service (All Pres- Some fluids require special packing and should be re-
sures) – Solid metal pistons with grooves and metal ferred to the factory.
snap rings or non–metallic rings with expanders are
recommended. Piston ring grooves have the proper Fluid Piston Rod Baffle – All pumps are supplied with
clearance but it is necessary to check rings for end an oil resistant rubber baffle which is mounted on the
clearance. Insert each ring in the cylinder liner and piston rod between the piston rod stuffing box and the
check end clearance with a feeler gauge. Metal rings oil stop head. The baffle must be kept in place to pre-
should have from .003” (.076 mm) to .004” (.1 02 mm) vent foreign material following along the piston rod from
per inch (25.4 mm) of ring diameter and nonmetallic the stuffing box into the power end.
should have from .006” (.152 mm) to .008” (.203 mm)
per inch (25.4 mm) of ring diameter.
High Pressure Pistons For Abrasive Service – For
high pressure slush service or mud with abrasive par-
ticles, a regular oil field rubber type piston is recom- Warranty is void if this baffle is not in
mended.
place.
High Temperature Service – Consult the Factory for
recommendations.
Fluid Piston Rod Packing – Braided synthetic pack- Frame Oil Stop Head Packing – Oil stop head pack-
ing is standard for water, oil and general service. Maxi- ing is cut square fibrous rings. The packing should be
mum service ratings for this packing are 250 PSI and inspected frequently and adjusted if necessary. Re-
250_ F. place when worn.
Molded convex packing is standard for mud service.
Maximum rated service temperature is 180_ F. Fluid Cylinder Liner Packing – Current liner packing
construction consists of two ”square rubber hydraulic
Molded rubber and duck packing is standard for grout rings” with a metal spacer between them and is suitable
and cement service and optional for other services. for most services.

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 Never tighten liner jack screws while
pump is running. If the screws are
drawn up too tight, enough pressure
can be put on the packing to crush the
liner. This ruins the liner, is apt to ruin
the piston and can cause piston rod
breakage.

Whenever the cylinder head is removed for any reason, FIGURE 6 – PISTON ROD
the liner jack screws must be backed out. Jack screws
should be greased to increase life of screws and cylin-
der heads and also to prevent rust formation.

When the cylinder head is replaced, the head to cylin- seats and the bore in the deck must be perfectly clean
der stud nuts should be tightened completely. AFTER and free from oil or grease.
the head nuts are tight, the liner jack screws should be
adjusted against the liners and the locknuts tightened. Valve seats can be removed with a puller which can be
Be sure packing is installed under set screw nuts to pre- purchased from Gardner Denver Machinery Inc.
vent leakage
STARTING A NEW PUMP – Pumps are shipped from
Some pumps are equipped with a clamp located the factory without oil in the crankcase. The hood
against the end of the liner and serves as a face for the should be removed and the power end examined and
set screws to bear against. For the proper tightening cleaned if necessary. The pump may have been in stor-
torques refer to torque table, page 18. age or in the yard for some time and as a consequence
dirt may have entered the crankcase. Parts may have
FLUID END PARTS – Standard procedure for shipping been robbed from the pump during storage and not re-
pumps from the Factory is with valves, pistons, liners, placed. All nuts and screws should be tightened.
piston rods and packing installed. These fluid end ex-
pendable parts are shipped unassembled only when The jackshaft bearings have been supplied with grease
requested by the customer. at the factory and no grease should be added at this
time, unless bearings have been disturbed.
FLUID CYLINDER LINERS – Liners should be
installed in accordance with instructions given under Be sure all valves in the discharge line are open. No
heading ”Fluid Cylinder Liner Packing”, page 9. Clean valve should be installed between the pump and pres-
liners thoroughly and grease the outside diameter be- sure relief valve in discharge line.
fore installing. Liner jack screws should be tightened as
uniformly as possible. To prevent excessive wear on the fluid pistons and
packing when starting, remove a suction valve cover
PISTON RODS – Pistons should be assembled on the plate on each side of the fluid end and prime the pump.
rod taper WITH THE THIN NUT NEXT TO THE PIS- Pump should be started slowly, if possible, and should
TON HUB AND THE THICK NUT ON THE OUTSIDE. be operated for several hours with practically no dis-
This is important as the outer nut carries the load. Slush charge pressure. Check oil level as it may be neces-
service rods use one elastic collar–type locknut per sary to add a small quantity of oil to compensate for that
rod. Rods should be threaded into the crosshead as adhering to the walls of the crankcase and the moving
shown in FIGURE 6, leaving approximately one thread parts. The pump may then gradually be brought up to
of the locknut over the relieved portion of the rod as a full speed and full working pressure. Watch for undue
protection to the threads. heating or abnormal noise in the working parts. Check
all joints in the suction line to be sure there are no air
FLUID VALVES – Valves are easily installed in their in- leaks.
dividual valve pots. Care should be exercised to tighten
the valve cover nuts as uniformly as possible, tighten- Make certain pump is rotating in the correct direction.
ing each nut a little at a time until all are tight. Valve Refer to FIGURE 7, page 11.

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 PREFERRED ROTATION OF ECCENTRIC
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FIGURE 7 – ROTATION OF ECCENTRIC

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 SECTION 3
ROUTINE MAINTENANCE & SERVICE INSTRUCTIONS

FIGURE 8 – JACKSHAFT ASSEMBLY

Daily Care – The pump should be kept clean, lubri- bly. To remove the gear and eccentric, it is necessary
cated properly and stuffing boxes examined daily. With to remove the main shaft. The main shaft must be re-
reasonable care, the pump can be expected to give moved from the side of the pump in which the end of the
long and trouble–free life. shaft contains a 3/4–10 UNC tapped hole. This is the
end of the shaft that also contains the main shaft to ec-
Occasional Inspection – It is recommended that the
centric key. (See FIGURE 9.) It is advisable to have
fluid valves be examined occasionally to see that ex-
new shaft seals as these seals can rarely be used the
cessive wear or cutting has not impaired their efficiency
and any damaged or worn parts should be replaced.
Fluid end must always be drained when exposed to
freezing weather during idle periods.
SERVICE INSTRUCTIONS
Removal of Jackshaft – To remove the jackshaft, it is
necessary to remove the bearing housings from both
sides of the pump. The bearing outer races and rollers
come off with the housings. The bearings inner races
and the seal bushings are pressed on the jackshaft and
need not be removed unless replacement is necessary.
The jackshaft can be lifted clear of the gear teeth and
removed. The jackshaft is not interchangeable end for
end, hence, it must be reinstalled in the same way it
was removed.
Installation of Jackshaft Oil Seals – The jackshaft
roller bearings are provided with a separate inner and
outer oil seal. The correct assembly of these seals is
with seal lips facing bearings.
To Remove Crosshead Pin From FXF and FXG
Pumps – The crosshead pin can be removed from the
FXF and FXG only by removing the entire gear assem- FIGURE 9 – ECCENTRIC AND MAIN SHAFT ASSEMBLY

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 To Install Main Bearings For All Pumps –

1. Install eccentric with gear teeth in correct position

in frame.

2. Install main shaft through opening in frame and

through eccentric.

3. Heat and press bearing cones to shaft.

4. Install bearing cups.

A41503 There should be no space between

the bearing cones and seal bushing
or between the seal bushing and ec-
FIGURE 10 – CROSSHEAD PIN REMOVAL–FXX, FXD & FXE centric hub.

second time. Remove shaft through eccentric with 5. Install gasket and end plate on one side.
hammer and wood block and the bearing cone and seal 6. Take up end plate on other side snugly with cap
bushing on the side opposite the tapped hole will slip off screws.
the shaft.
7. Check the gap between plate and frame housing
The gear assembly with connecting rods and cross- with shims. Determine shims required to fill the
heads can all be pulled out through the hood opening gap. When you have determined the shims re-
after the main shaft has been removed. The piston rods quired to fill the gap, remove 0.001 to 0.003 inches
of course must be screwed out of the crossheads be- (0.0254 to 0.0762 mm) of shims.
fore the assembly can be taken from the frame. Cross-
head pins are straight and are held in place in the cross- 8. Remove end plate and install remaining shims.
heads with set screws.
9. Mount and secure plate.
To Remove Crosshead Pin From FXX, FXD and
FXE Pumps – The inspection plates on the sides of the FXE Main Gear and Eccentric – This pump is
frame should be removed. Two hexagon head cap constructed with a separate gear bolted to the eccen-
screws are used to hold the crosshead pin to the cross- tric. Refer to page 18 for screw torque specifications.
head. These are the two screws in the corners of the
plate over the crosshead pin. Take these screws out MAINTENANCE OF SPARE REPAIR PARTS – Al-
and insert them in the tapped holes in the adjacent cor- though operating conditions vary widely, it is suggested
ners of the plate and by exerting sufficient pressure that a stock of spare replacement parts be maintained
with these screws the crosshead pin will come out. A to insure against loss of pump operation. It is consid-
little persuasion with a drift driven against the cross- ered good practice to keep spare fluid valves, pistons,
head near the outer end of the crosshead pin will help. piston rods, packings, gaskets, etc. on hand. A recom-
mended list of such parts may be secured from Gard-
To remove the gear and eccentric it is necessary to re- ner Denver Customer Service, the Master Distribution
move the main shaft and piston rods. The main shaft Center (MDC), or your local authorized Gardner Den-
must be removed from the side of the pump in which the ver Distributor.
shaft contains a 3/4–10 UNC tapped hole. This is the
end of the shaft that also contains the main shaft to ec- ORDERING OF REPAIR PARTS – Repair parts lists
centric key. (See FIGURE 9, page 12.) Support eccen- with sectional views are available for any Gardner Den-
tric on blocking and drive shaft through eccentric with ver
power pump and may be secured from Gardner
hammer and wood block. The bearing cone and seal Denver Customer Service, the Master Distribution
sleeve, on the side opposite the tapped hole, will slip off Center (MDC), or your local authorized Gardner Den-
the shaft. ver Distributor.

3–600 Page 13

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 When ordering parts lists or repairs, always give size
and serial number of pump. Serial number is stamped
on the pump nameplate attached to frame and also on
a raised pad located on upper side of the power frame
at the fluid cylinder end. Pressures are maximum permissible
with rated maximum piston rod loads
If the serial number cannot be identified, obtain several
photographic views of the power frame and fluid cylin-
and MUST NEVER BE EXCEEDED.
ders, including part numbers of principal castings
which should furnish us clues as to the identity of the
While it is true that reducing the speed reduces the
pump.
horsepower practically in direct proportion, the piston
load for which the pump is designed is a function of the
SPECIAL CARE OF PUMP IN STORAGE – Piston rod fluid pressure against the piston. Reducing the speed
packing and piston packing must be removed, if the to half and doubling the pressure requires approxi-
pump is not put in service immediately. Permitting mately the same horsepower but results in 100% over-
packing to remain in an idle pump for a period of time load on the power end.
will tend to create rusting and pitting of liner bore and
piston rods. Maximum input BHP and shaft RPM shown in bulletins
MUST NEVER BE EXCEEDED under any operating
Puller kit parts for removing valve seats, liners and conditions. These speeds are recommended for favor-
crosshead pin bushings may be purchased from Gard- able suction conditions and consideration must be giv-
ner Denver Machinery Inc. en to viscosity and character of fluid.

OPERATING SPEEDS AND PRESSURES – See bul-

letins for operating speeds and pressures for type of
service.
DO NOT operate these pumps below
All displacements are theoretical with piston rod vol- 40 RPM as this will hinder proper lu-
ume deducted. For actual delivery deduct from 5% to brication.
10% for slippage using 10% at maximum RPM.

3–600 Page 14

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 SECTION 4
DIMENSIONS & RUNNING CLEARANCES

POWER END OIL STOP HEAD DIMENSIONS

Stuffing Box Net Depth Of

Power Size Rod Diameter Diameter Stuffing Box
End
Model Inches mm Inches mm Inches mm Inches mm

FXF 5 127 15/16 23.8125 1–3/4 44.45 7/8 22.225

FXG 6 152.4 1 25.4 1–13/16 46.0375 7/8 22.225

FXX 8 203.2 1–1/2 38.1 2–1/2 63.5 1–1/8 28.575

FXD 10 254 1–1/2 38.1 2–1/2 63.5 1–5/8 41.275

FXE 10 254 1–1/2 38.1 2–1/2 63.5 1–5/8 41.275

FLUID END PISTON ROD STUFFING BOX DIMENSIONS

* Stuffing Box Net Depth Of

Power Fluid Size Rod Diameter Diameter Stuffing Box
End End
Model Type Inches mm Inches mm Inches mm Inches mm

FXF ALL 4x5 101.6 x 127.0 15/16 23.8125 1–3/4 44.45 2–1/16 52.3875

FXG ALL 5x6 127.0 x 152.4 1 25.4 1–13/16 46.0375 2–3/8 60.325

FXX D, H, 5x8 127.0 x 203.2 1–1/2 38.1 2–1/2 63.5 1–1/8 28.575
FXD M, Q, or or 1–1/2 38.1 2–1/2 63.5 3–1/8 79.375
FXE &U 5 x 10 127.0 x 254.0

B, C, 5x8 127.0 x 203.2 1–1/2 38.1 2–1/2 63.5 1–1/8 28.575

FXX F, G, or or 1–1/2 38.1 2–1/2 63.5 3–1/8 79.375
FXD K, L, 5 x 10 127.0 x 254.0
FXE P, S,
&T

FXX A, E, 5x8 190.5 x 203.2 1–1/2 38.1 2–1/2 63.5 1–1/8 28.575
FXD J, N, or or 1–1/2 38.1 2–1/2 63.5 3–1/8 79.375
FXE &R 5 x 10 190.5 x 254.0

* Refer to Unit Nameplate and Parts List Manual Matrix, Column 4, for Fluid Cylinder Descriptions.

3–600 Page 15

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 DATA FOR FXD, FXE, AND FXX POWER PUMPS

POWER END AND STROKE

RECOMMENDED RUNNING CLEARANCES FXD & FXE FXX

(Actual dimensions are for new pumps and are 10 In. (254.0 mm) Stroke 8 In. (203.2 mm) Stroke
possible cumulative tolerances.) (Condemnable
indicates replacement necessary.) Inches mm Inches mm

Min. Max. Min. Max. Min. Max. Min. Max.

a. ROLLER TYPE MAIN BEARINGS

Refer to Page 13.
Bearing Preload .001T .003T .025T .076T .001T .003T .025T .076T
Condemnable when pitting, scaling, mis–
alignment, excessive wear or noise occurs.

b. CONNECTING ROD LINER TO ECCENTRIC

Actual .011 .022 .279 .559 .009 .017 .229 .432
Feeler Gauge .010 .021 .254 .533 .008 .016 .203 .406
Condemnable when liner knocks or
clearance equals .040 1.016 .035 .889

c. CROSSHEAD PIN
Feeler Gauge .0015 .002 .038 .051 .0015 .002 .038 .051
Condemnable – Replace pressed–in type
bushings when a .006” (.152 mm) feeler
gauge can be inserted between the pin and
bushing or when the crosshead pin knocks.

d. CROSSHEAD OR SHOE TO FRAME

Actual .005 .013 .127 .330 .005 .013 .127 .330
Feeler Gauge .004 .012 .102 .305 .004 .012 .102 .305
Condemnable when crosshead knocks or
clearance equals .060 1.524 .060 1.524

e. JACKSHAFT ROLLER BEARING

Condemnable between roller and race
.016 – .018” (.406 – .457 mm).

GEAR RATIO 6.0 4.71

3–600 Page 16

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 DATA FOR FXG AND FXF POWER PUMPS

POWER END AND STROKE

RECOMMENDED RUNNING CLEARANCES FXG FXF

(Actual dimensions are for new pumps and are 6 In. (152.4 mm) Stroke 5 In. (127.0 mm) Stroke
possible cumulative tolerances.) (Condemnable
indicates replacement necessary.) Inches mm Inches mm

Min. Max. Min. Max. Min. Max. Min. Max.

a. ROLLER TYPE MAIN BEARINGS

Refer to Page 13.
Bearing Preload .001T .003T .025T .076T .001T .003T .025T .076T
Condemnable when pitting, scaling, mis–
alignment, excessive wear or noise occurs.

b. CONNECTING ROD LINER TO ECCENTRIC

Actual .007 .015 .178 .381 .006 .014 .152 .356
Feeler Gauge .006 .014 .152 .356 .005 .013 .127 .330
Condemnable when liner knocks or
clearance equals .030 .762 .030 .762

c. CROSSHEAD PIN
Feeler Gauge .0005 .0010 .0127 .0254 .0005 .0010 .0127 .0254
Condemnable – Replace pressed–in type
bushings when a .006” (.152 mm) feeler
gauge can be inserted between the pin and
bushing or when the crosshead pin knocks.

d. CROSSHEAD OR SHOE TO FRAME

Actual .003 .010 .076 .254 .003 .010 .076 .254
Feeler Gauge .002 .009 .051 .229 .002 .009 .051 .229
Condemnable when crosshead knocks or
clearance equals .060 1.524 .060 1.524

e. JACKSHAFT ROLLER BEARING

Condemnable between roller and race
.016 – .018” (.406 – .457 mm).

GEAR RATIO 4.72 4.88

3–600 Page 17

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 TORQUE SPECIFICATIONS

POWER FXD _ FXD _ FXD _ FXF

END FXE _ FXE _ FXE _ FXG
MODEL FXX _ FXX _ FXX _

A B D
* FLUID E C H
CYLINDER J F M ALL
TYPE N G Q
R K U
(Column 4 L
of Matrix) P
S
T

ft–lbs kg–m ft–lbs kg–m ft–lbs kg–m ft–lbs kg–m

Fluid Cylinder to Frame 210 29.0 590 81.6 590 81.6 260 36.0
Connecting Stud Nuts

Fluid Cylinder ––– ––– ––– ––– 590 81.6 ––– –––
Head Stud Nut

Fluid Cylinder Liner 25 3.5 25 3.5 25 3.5 25 3.5

Set Screw

Suction Manifold to ––– ––– ––– ––– 260 36.0 ––– –––
Fluid Cylinder

Discharge Manifold to ––– ––– ––– ––– 260 36.0 ––– –––
Fluid Cylinder

Suction Manifold 260 36.0 260 36.0 260 36.0 150 20.7
Flange Nut

Discharge Manifold 260 36.0 ––– ––– 800 110.6 150 20.7
Flange Nut

Piston Rod Nut 525 72.6 525 72.6 525 72.6 260 36.0
(Slush–Proof Rod)

FXE ONLY
ft–lbs kg–m
Main Gear to Eccentric Screw 75 10.4

* Refer to Unit Nameplate and Parts List Manual Matrix, Column 4, for Fluid Cylinder Descriptions.

3–600 Page 18

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 SECTION FIVE
TROUBLESHOOTING

FAILURE TO DELIVER REQUIRED VOLUME:

(a) Pump not primed.
(b) Insufficient speed.
(c) Fluid liner worn.
(d) Suction lift too high.
(e) Air leaks in suction or stuffing boxes.
(f) Foot valve too small or clogged.
(g) Suction pipe not immersed deep enough.
(h) Fluid piston packing worn.
(i) Fluid valves worn.
(j) Insufficient prime mover horsepower.
(k) Piston loose on rod.
FAILURE TO CREATE RATED PRESSURE:
(a) Insufficient prime mover horsepower.
(b) Slippage in drive.
(c) High back pressure.
(d) Piston rings in fluid end binding.
(e) Pistons improperly packed.
(f) Valves not holding.
(g) Leakage past fluid piston rings.
(h) Leakage past liner packing.
(i) Liners worn.
PUMP LOSES CAPACITY AFTER STARTING:
(a) Leaky suction line.
(b) Suction lift too great.
(c) Entrained vapors in the fluid, especially if fluid is
warm.
PUMP VIBRATES
(a) Fluid pistons improperly packed.
(b) Foundation not sufficiently rigid.
(c) Fluid piston packed too tight.
(d) Fluid valves improperly seated.
(e) Improper discharge line.
NOISY FLUID VALVES:
(a) Usually due to air leaks or failure of the fluid end to
completely fill due to faulty suction conditions.
(b) Valves not seating tightly.

3–600 Page 19

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 WARRANTY
GARDNER DENVERR D OPIR PUMPS

GENERAL PROVISIONS AND LIMITATIONS Labor shall be limited to the amount specified in the
Company’s labor rate schedule.
Gardner Denver Machinery Inc. (the “Company”) war-
rants to each original retail purchaser (“Purchaser”) of its Labor costs in excess of the Company rate schedules
new products from the Company or its authorized distrib- caused by, but not limited to, location or inaccessibility
utor that such products are, at the time of delivery to the of the equipment, or labor provided by unauthorized ser-
Purchaser, made with good material and workmanship. vice personnel is not provided for by this warranty.
No warranty is made with respect to: All costs of transportation of product or parts claimed not
1. Any product which has been repaired or altered to be as warranted and, of repaired or replacement parts
in such a way, in the Company’s judgment, as to to or from such service facility shall be borne by the Pur-
affect the product adversely. chaser. The Company may require the return of any part
claimed not to be as warranted to one of its facilities as
2. Any product which has, in the Company’s judg- designated by the Company, transportation prepaid by
ment, been subject to negligence, accident, im- the Purchaser, to establish a claim under this warranty.
proper storage, or improper installation or ap-
plication. Replacement parts provided under the terms of this war-
ranty are warranted for the remainder of the Warranty
3. Any product which has not been operated or Period of the product upon which installed to the same
maintained in accordance with the recommen- extent as if such parts were original components.
dations of the Company.
WARRANTY REGISTRATION VALIDATION
4. Components or accessories manufactured,
warranted and serviced by others. A warranty registration form is provided with each ma-
chine. The form must be completed by the Purchaser
5. Any reconditioned or prior owned product. and mailed within ten days after machine start–up to vali-
date the warranty.
Claims for items described in (4) above should be sub-
mitted directly to the manufacturer. DISCLAIMER
WARRANTY PERIOD THE FOREGOING WARRANTY IS EXCLUSIVE AND
IT IS EXPRESSLY AGREED THAT, EXCEPT AS TO
The Company’s obligation under this warranty is limited TITLE, THE COMPANY MAKES NO OTHER WAR-
to repairing or, at its option, replacing, during normal RANTIES, EXPRESSED, IMPLIED OR STATUTORY,
business hours at an authorized service facility of the INCLUDING ANY IMPLIED WARRANTY OF MER-
Company, any part which in its judgment proved not to CHANTABILITY.
be as warranted within the applicable Warranty Period
as follows. THE REMEDY PROVIDED UNDER THIS WARRANTY
SHALL BE THE SOLE, EXCLUSIVE AND ONLY REM-
Except for the products or components listed below, the EDY AVAILABLE TO PURCHASER AND IN NO CASE
Warranty Period for all products is 1,250 hours of opera- SHALL THE COMPANY BE SUBJECT TO ANY
tion or three (3) months after start–up, not to exceed 120 OTHER OBLIGATIONS OR LIABILITIES. UNDER NO
days after delivery to Purchaser, whichever occurs first. CIRCUMSTANCES SHALL THE COMPANY BE
The exceptions are as follows: LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL
1. Power end is warranted for twelve (12) months OR CONSEQUENTIAL DAMAGES, EXPENSES,
from date of start–up or eighteen (18) months LOSSES OR DELAYS HOWSOEVER CAUSED.
from date of delivery to the Purchaser, whichev- No statement, representation, agreement, or under-
er occurs first. standing, oral or written, made by any agent, distributor,
2. Forged steel fluid cylinder is warranted for 90 representative, or employee of the Company which is
days from date of installation. not contained in this Warranty will be binding upon the
Company unless made in writing and executed by an of-
3. Expendable fluid end parts, including, but not ficer of the Company.
limited to, valves, valve parts, packing, liners
and pistons, are not covered by this warranty This warranty shall not be effective as to any claim which
due to variable abrasive nature of material is not presented within 30 days after the date upon which
pumped. the product is claimed not to have been as warranted.
Any action for breach of this warranty must be com-
LABOR TRANSPORTATION AND INSPECTION menced within one year after the date upon which the
The Company will provide labor, by Company represen- cause of action occurred.
tative or authorized service personnel, for repair or re- Any adjustment made pursuant to this warranty shall not
placement of any product or part thereof which in the be construed as an admission by the Company that any
Company’s judgment is proved not to be as warranted. product was not as warranted.

BE–13 R 10/96

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