GARDNER DENVER® 1st Edition

April, 2002

WELL SERVICING PUMP

MODEL

LC 1000 / LC 1200A

OPERATING AND
SERVICE MANUAL
 LC 1000
WELL SERVICING PUMP
MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER
PARTS AND SUPPORT SERVICES

Gardner Denver® genuine pump parts are manufactured to design tolerances and are developed for
optimum dependability. Design and material innovations are the result of years of experience with
hundreds of different pump applications. Reliability in materials and quality assurance is incorporated
in our genuine replacement parts.

Your authorized Gardner Denver Sales Office offers all the backup you’ll need. The Fort Worth
Manufacturing Facility maintains a large inventory of genuine parts.

Gardner Denver supports your needs with these services:

1. Trained parts specialists to assist you in selecting the correct replacement parts.
2. Repair and maintenance kits designed with the necessary parts to simplify servicing your pump.

Authorized service technicians are factory trained and skilled in pump maintenance and repair. They
are ready to respond and assist you by providing fast, expert maintenance and repair services.

For the location of your local authorized Gardner Denver distributor, refer to the yellow
pages of your phone directory or contact:

Factory (Tulsa): Factory (Ft. Worth):

Gardner Denver Well Servicing Pumps Geoquip
4747 South 83rd East Avenue 7533 Kathy Lane
Tulsa, Oklahoma 74145 Ft. Worth, Texas 76126

Phone: (918) 664-1151 Phone: (817) 249-6400

(800) 738-8099 (800) 824-0271

Fax: (918) 664-6225 Fax: (817) 249-6401

INSTRUCTIONS FOR ORDERING REPAIR PARTS

When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
The Serial Number is also stamped on top of the cylinder end of the frame (cradle area).

All orders for Parts should be placed with the Tulsa or Ft. Worth facility.

Where NOT specified, quantity of parts required per pump or unit is one (1); where more than
one is required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER
OF PARTS REQUIRED.

Page i
 FOREWORD

Gardner Denver® pumps are the result of advanced engineering and skilled manufacturing. To
be assured of receiving maximum service from this pump the owner must exercise care in its
operation and maintenance. This book is written to give the operator and maintenance personnel
essential information for day-to-day operation, maintenance and adjustment. Careful adherence
to these instructions will result in economical operation and minimal downtime.

DANGER

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

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

CAUTION

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

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

information which is important but not hazard related.

Page ii
 TABLE OF CONTENTS

Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and
Support Services................................................................................................................ i

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

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

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

List of Illustrations ...................................................................................................................... v

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

Section 2, Design, Description and Specifications .................................................................... 9

Section 3, Preparation, Operation and Maintenance................................................................. 15

Section 4, Service Procedures .................................................................................................. 21

Section 5, Trouble-Shooting ...................................................................................................... 27

Section 6, Rebuilding Data, Recommended Running Clearances ........................................... 33

Torques for Bolts, Studs, and Nuts……………………………………………………………………34

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

Page iii
 INDEX
Crankshaft Assembly ....................................25 Performance Rating......................................... 14

Crosshead Assembly … ...............................24 Periodic Routine Maintenance Schedule ........ 18

Crosshead Guides …....................................24 Plunger / Packing Lubrication.......................... 17

Daily Routine Maintenance Schedule...........19 Plunger Packing Lubrication Recommendation

Chart.......................................................... 20
DANGER NOTICES, SECTION 1 ..................1
Plungers and Packing Replacement ............... 22
Covers and Guards.................................2
Power End .................................................. 10,24
Equipment Moving and Lifting ................2
Power End and Gear Reduction
Flammable, Hot, Cold or Corrosive Unit Lube System...................................... 12
Fluid Pumping.................................5
Power End Lubrication System ....................... 16
Hammer Lug Fasteners……………….. ..1
Preparation after Shipping and Storage .......... 15
High Pressure Liquid Jetting,
Blasting and Cleaning.....................6 PREPARATION, OPERATION AND
MAINTENANCE, SECTION 3................... 15
Pressurized Pump Systems....................3
Pump Design ................................................... 10
Valve Seat Pulling...................................2
Pump Mounting Instructions ............................ 15
DESIGN DESCRIPTION AND
SPECIFICATIONS, SECTION 2.............9 Quarterly Routine Maintenance Schedule....... 19

Fluid End Description....................................13 Rebuilding Data ............................................... 34

Fluid End Removal and Installation ..............21 REBUILDING DATA, RECOMMENDED

RUNNING CLEARANCES AND
Fluid End Service..........................................21 TORQUES, SECTION 6 ........................... 34

Foreword …………………………………..…. .. ii Recommended Running Clearances – Actual 34

Gear Reduction Unit ................................11,26 Repair Parts, Ordering Instructions .....................i

General Requirements and Safety Rules .....21 SERVICE PROCEDURES, SECTION 4 ......... 21

General Specifications ..................................14 Specifications, General.................................... 14

Introduction .....................................................9 Startup and New Pump Run-In Procedure...... 17

Lube Pump Suction Piping Sizing and Torques............................................................ 34

Requirements........................................16
TROUBLE-SHOOTING, SECTION 5 .............. 27
Lube System Pump.......................................16
Warranty ................................................... Last
Lubrication, Plunger / Packing ......................17 Page

Monthly Routine Maintenance Schedule ......19 Valve and Seat Replacement .......................... 22

Oil Stop Head Seal Retainer and Crosshead

Slides, Pin Retainer Plate ....................24

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

Page iv
 LIST OF ILLUSTRATIONS

Figure # Description Page

Figure 2-1 LC 1000 Triplex Pump............................................................................... 9

Figure 2-2 LC 1000 Power End .................................................................................. 10

Figure 2-3 LC 1000 Power End Top View .................................................................. 11

Figure 2-4 LC 1000 Gear Reduction Unit ................................................................... 12

Figure 2-5 LC 1000 Fluid End..................................................................................... 13

Figure 3-1 Lubricant Recommendations..................................................................... 17

Figure 4-1 Fluid End Assembly................................................................................... 22

Figure 4-2 Packing Assembly ..................................................................................... 22

Figure 4-3 Crosshead Assembly ................................................................................ 25

Page v
SECTION 1
DANGER NOTICES

The timely replacement of expendable parts

DANGER and any other worn or damaged parts can
prevent equipment damage and possible
Read and understand the following injury. The original parts used in Gardner
DANGER NOTICES before moving or Denver pumps are designed and tested to
operating the pump or any pump package exacting standards to provide high quality
unit equipment. performance and durability. Your best
insurance in maintaining these
Reciprocating pumps are machines capable characteristics is to use genuine Gardner
of producing high fluid pressures and flow Denver replacement parts.
rates and are designed to be used with
proper care and caution by trained, A broad range of danger notices are
experienced operators. TO AVOID covered on these pages, however, they
PERSONAL INJURY, DEATH AND/OR cannot substitute for training, experience
EQUIPMENT DAMAGE, READ AND and common sense in the safe operation of
THOROUGHLY UNDERSTAND THE high pressure pumping equipment.
FOLLOWING DANGER NOTICES PLUS
THE ENTIRE OPERATING AND SERVICE
MANUAL BEFORE ATTEMPTING TO HAMMER LUG FASTENERS
MOVE OR OPERATE THE PUMP. Contact
a Gardner Denver service representative if
you are unable to comply with any of the DANGER
danger notices or procedures described in
these documents. On pumps equipped with hammer lug
unions and/or hammer lug valve covers the
Closely examine the pump performance following precautions must be observed to
data upon pump delivery to become avoid personal injury, death and/or
thoroughly familiar with the operating limits equipment damage due to contact with the
for this pump model. The pump must hammer, broken parts from the hammer,
never be operated at speeds, pressures lugs or other objects propelled by hammer
or horsepower exceeding the maximum blows. When tightening or loosening
values or at speeds below the minimum. hammer lug unions and valve covers,
Failure to observe the operating limits operators or maintenance personnel should:
could result in personal injury, death,
and/or equipment damage and will void Inspect the hammer and hammer lugs
the warranty. Alterations to the pump, or to insure they are all in good condition.
application of the pump outside the limits, Replace any of these parts which are
must not be made without Gardner Denver cracked, damaged or badly worn.
written approval, together with a new set of
performance data, as dangerous operating Wear safety shoes and safety glasses.
conditions could result.
Alert other personnel to move away
Keep in mind that full operator attention and from the area.
alertness are required when operating high
pressure pumping equipment. Operators Check to insure they have safe footing.
should not begin or continue operations
when tired, distracted or under the influence Fully engage the hammer bar, if one is
of alcohol or any type of prescription or used, to prevent it from disengaging
nonprescription drugs. violently from the cover as a blow is
struck.

Page 1
 Wipe their hands and the hammer Check to insure they have safe footing.
handle and maintain a firm grip on the
handle to avoid losing control of the Fully engage the wedge to prevent it
hammer while swinging and striking. from disengaging violently from the
cover as a blow is struck.
Carefully swing the hammer to avoid
striking themselves, another person and Wipe their hands and the hammer
objects other than the targeted lugs or handle and maintain a firm grip on the
hammer bar. handle to avoid losing control of the
hammer while swinging and striking.
Avoid swinging the hammer above
shoulder height. Carefully swing the hammer to avoid
striking themselves, another person and
objects other than the targeted wedge.
VALVE SEAT PULLING
Avoid swinging the hammer above
shoulder height.
DANGER
COVERS AND GUARDS
The following precautions must be observed
by operators and maintenance personnel to
avoid personal injury, death and/or
equipment damage from contact with the DANGER
puller, hammer, wedge or broken parts from
these components when using either a Personal injury, death and /or
hydraulic or wedge valve seat puller. equipment damage can result from
Operators or maintenance personnel
should:
contact with moving parts. All
moving parts must be equipped with
Hydraulic Seat Puller covers and guards. All covers and
guards must be securely positioned
Wear safety shoes and glasses. at all times when the unit is in
operation.
Chain or tie the jack down as it will jump
violently when the valve seat
disengages from the valve deck. Covers and guards are intended to not only
protect against personal injury or death, but
Check to insure the pressure applied by to also protect the equipment from foreign
the hydraulic pump does not exceed the object damage
hydraulic ram maximum pressure rating.

Wedge Seat Puller EQUIPMENT MOVING AND LIFTING

Grind off any mushroomed material from

the wedge before use. DANGER

Inspect the hammer and wedge to Heavy equipment including pumps, pump
insure they are in good condition. packages and components should only be
Replace any of those parts which are moved or lifted by trained, experienced
cracked, damaged or badly worn. operators, who are physically and mentally
prepared to devote full attention and
Wear safety shoes and goggles. alertness to the moving and lifting
operations. An operator should be fully
aware of the use, capability, and condition of

Page 2
both the equipment being moved and the as fully assembled should be separated into
equipment being used to move it. smaller loads.
For these smaller loads the lifting devices
should be fastened to the lifting attachments
DANGER normally built into the individual motor,
engine, pump or transmission / torque
Failure to follow safe and proper converter, or their separate support skids.
pump, pump package or component
When lifting subassembled components, for
lifting or moving procedures can lead example a suction stabilizer attached to
to personal injury, death and /or suction piping or a discharge pulsation
equipment damage from shifting, damper attached to a strainer cross and
falling or other unexpected or piping, use special lifting slings designed to
uncontrolled equipment movements. safely support the combined weight of the
components.

Make sure the hoist, lift truck, ropes, slings, If a crane or hoist is being used to lift large
spreader bar or other lifting equipment you components or assemblies, one or more
are using is in good condition and has a persons should assist the operator from the
rated lifting capacity equal to or greater than ground with guide lines attached to the
the weight being lifted. Lifting devices must equipment being moved to properly position
be checked frequently for condition and it and prevent uncontrolled movement.
continued conformance to rated load
capacity. They should then be tagged with When you start to lift a pump, package unit,
the rated capacity together with the date of subassemblies or individual components
inspection. and you observe the equipment is tilting, or
appears unbalanced, lower the equipment
Fully assembled pumps and pump and adjust the lifting device to eliminate
packages are heavy and should only be these improper lifting conditions before
moved using the specified lifting lugs or proceeding to move the equipment.
attachments.
It is poor practice and dangerous to allow
Many individual components have lifting the equipment to pass over or close to your
eyes or lugs which must not be used to body or limbs. Be prepared to move quickly
lift assemblies, as they are designed to out of danger if equipment starts to fall, slip
bear the weight of the component only. or move unexpectedly toward you.

Before lifting the individual component

check to insure the lifting attachment is PRESSURIZED PUMP SYSTEMS
firmly secured to the component with
undamaged, properly torqued fasteners,
sound welds, or other secure attachments.
Examine the lifting eyes, lugs, slots, holes or DANGER
other projections to insure they are not
cracked, otherwise damaged or badly worn. Fluids under high pressure can
The repair of existing or addition of new possess sufficient energy to cause
welded lifting eyes, lugs or other projections personal injury, death and/or
should only be performed by experienced, equipment damage either through
qualified welders.
direct contact with escaping fluid
Package units should be lifted with streams or by contact with loose
spreaders connected to the lifting objects the pressurized fluid propels.
attachments normally built into the package
unit support skid. Packages too large to lift

Page 3
Operating a pump against a blocked or The pressure relief valve is in good
restricted discharge line can produce operating condition and has been set to
excessive pressures in the entire discharge the proper relief pressure.
system, which can damage or burst
discharge system components. Any pipe line used to direct pressurized
relief flow to another location, such as a
collecting tank, is not blocked.

DANGER The discharge system is not blocked

and all the discharge line valves are
Never operate a pump without a open.
properly sized pressure relief valve or
working overpressure shutdown in Check all fluid end discharge system
components including pipes, elbows
the discharge line immediately
connections, threads, fasteners, hoses,
adjacent to the pump discharge. etc., at least once every six months to
confirm their structural adequacy. With
time, wear, corrosion and fatigue can reduce
The relief valve should be placed in the the strength of all components. Magnetic
flowing discharge line and not at the iron and steel components should be
opposite end of the discharge manifold in a checked with magnetic particle or dye
dead end connection. The dead end may penetrant crack detection equipment.
become clogged with solid material carried Nonmagnetic materials should be checked
in the fluid, which could prevent proper relief for cracks with dye penetrants. All metallic
valve operation. components should also be visually checked
during these inspections for signs of
corrosion. If a component shows evidence
of cracking or loss of material due to
DANGER corrosion it must be replaced with a new
part.
Never place a shut-off valve or any
other component between the pump Continually monitor suction and discharge
discharge connection and the hose assemblies when the pump is
pressure relief valve. operating for leakage, kinking, abrasion,
corrosion or any other signs of wear or
damage.
Make sure the pressure relief valve is
installed so any pressurized relief discharge Worn or damaged hose assemblies
from the valve is directed away from should be replaced immediately. At least
possible contact with people or equipment. every six months examine hose assemblies
The relief valve must be set to relieve at a internally for cut or bulged tube, obstructions
pressure equal to or below the maximum and cleanliness. For segment style fittings,
pressure values shown on the pump data be sure that the hose butts up against the
plate. However, if a component is used in nipple shoulder, the band and retaining ring
the discharge system with a lower rated are properly set and tight and the segments
pressure capability than that listed on the are properly spaced. Check for proper gap
pump data plate, the pressure relief valve between nut and socket or hex and socket.
must be set to relieve at a pressure equal to Nuts should swivel freely. Check the layline
or below the rated capability of the lowest of the hose to be sure that the assembly is
rated component. not twisted. Cap the ends of the hose with
plastic covers to keep them clean until they
Before starting the pump every time, are tested or reinstalled on the pump unit.
check to insure: Following this visual examination, the hose
assembly should be hydrostatically tested,

Page 4
on test stands having adequate guards to Whenever the pump is operating, continually
protect the operator, per the hose monitor the entire suction, discharge and
manufacturer's proof test procedure. pump lubricating systems for leaks.
Thoroughly investigate the cause for
Fluid end component inspections should leakage and do not operate the pump until
be performed more frequently than every the cause of the leak has been corrected.
six months if pressures above 2500 psi Replace any parts which are found to be
are used in the discharge system or if damaged or defective. When a gasketed
corrosive, abrasive, flammable or hot joint is disassembled for any reason, discard
(over 110º F) fluids are being pumped. the used gasket and replace it with a new,
genuine Gardner Denver gasket before
Proper stuffing box packing selection is reassembling the joint.
important for safe pump operation. Contact
a Gardner Denver service representative for Due to the high working pressures
assistance in selecting the proper packing contained by the fluid end, discharge
before beginning operation. manifold and discharge piping, welding on
these components is not recommended. If
Before starting the pump the first time, and welding on the discharge system cannot be
periodically thereafter check the pump, avoided, only experienced, qualified welders
suction and discharge system fastener should be used. In addition, the welded part
torques versus the values listed on page 35 should be hydrostatically proof tested in the
to insure proper tightness. Over and under shop with water or hydraulic fluid to one and
torquing can damage threaded pipes, one half times maximum discharge system
connections and fasteners, which may lead working pressure, with no observable fluid
to component damage and/or failure. leakage, before the part is reinstalled in the
Replace all components found to be pump system.
damaged or defective. On pumps equipped
with stuffing boxes, the gland must be In summary, high pressure fluid streams can
engaged by at least three (3) threads to hold possess sufficient energy to cause personal
the discharge pressure of the pump. injury, death and/or equipment damage.
These results can occur either through
direct contact with the fluid stream or by
contact with loose objects the fluid stream
DANGER has propelled, if the pump system is
improperly used, or if the fluid is
misdirected, or allowed to escape from
Do not attempt to service, repair or
defective or improperly maintained
adjust the plunger packing or other- equipment.
wise work on the pump while the unit
is operating. Shut off the pump drive
engine and relieve the fluid pressure FLAMMABLE, HOT, COLD OR
in the suction and discharge systems CORROSIVE FLUID PUMPING
before any work or investigation is
performed on the pump or pump
systems.
DANGER

Block the crankshaft from turning and make Extreme caution must be exercised
certain that all pump drive motor or engine by trained and experienced operators
start switches or starter controls are clearly when flammable, hot, cold or
tagged with warnings not to start the pump corrosive fluids are being pumped to
while repair work is in process.
avoid personal injury, death an/or

Page 5
equipment damage due to explosion, could form should be equipped with an air
fire, extreme cold or chemical attack. inlet shut-off. If flammable or explosive
vapors are present in the pumping site
Never operate a pump which is pumping atmosphere, an engine could continue to
hydrocarbons or other flammable, hot, cold, run on these vapors even after the engine
or corrosive fluids when any part of the fuel line is shut-off if an air inlet shut-off is
pump, suction system or discharge system not used.
is leaking. Stop the pump immediately if any
leakage, other than a few drops per minute In addition, on pumping units used where
of packing weepage, is observed. Keep all flammable or explosive vapors could form,
flame, sparks, or hot objects away from any all electric motors used as power sources
part of the pump, suction system, or must be of explosion proof construction and
discharge system. Shield the pump, suction all electrical components and wiring must
system and discharge system to prevent meet the current National Electrical Code for
any flammable, hot, cold or corrosive fluid explosive atmospheres.
leakage from dripping or spraying on any
components, flame, sparks, hot objects or These precautions must be taken to avoid
people. Inspect the plungers, packing, possible personal injury, death and/or
gaskets and seals for fluid leakage equipment damage from explosion, fire or
frequently and replace all worn or leaking burns.
parts.

Selection of the proper gaskets, seals and HIGH PRESSURE LIQUID JETTING,
stuffing box packing is even more critical BLASTING AND CLEANING
when flammable, hot, cold or corrosive fluids
are being pumped than when other,
inherently less dangerous fluids are used.
Contact a Gardner Denver service DANGER
representative for assistance in selecting the
proper gaskets, seals and packing before Extreme caution must be exercised if
beginning operation. any type of wand, gun, nozzle or any
other pressure and flow directing
Since some packing weepage into the device is attached to the pump
cradle area is inevitable, the drain at the discharge system for use in jetting,
bottom of the cradle must be connected to a
blasting, cleaning, etc. This type of
drain line which conducts the fluid leakage
to a collection container located in a equipment must be used by trained,
protected area. The entire drain system and experienced operators with the
container must be constructed of materials utmost care. High pressure fluid
resistant to attack from the pumped fluid or streams can either by direct contact
from explosion or fire of the pumped fluid. or by propelling loose objects, cause
serious personal injury or death to
Before beginning pumping operations or operators and/or other persons.
starting the pump power source (whether an
engine or electric motor) check the
atmosphere all around the pumping site for Pressure or flow directing devices often
the presence of flammable or explosive receive pressurized flow through flexible
vapors. Do not begin operation and stop hoses, which can burst if they are kinked,
ongoing operation if flammable or explosive cut, abraded or are otherwise worn,
vapors are detected. Hot surfaces, sparks, damaged or pressured above their rated
electric current or engine exhaust could capacity. Protect the hose and connections
ignite flammable or explosive vapors. Each from damage by people, objects and
engine used as a power source on pumping vehicles. A broken, cut or otherwise burst
units where flammable or explosive vapors hose can release pressurized fluid which

Page 6
may cause personal injury, death and/or equipment damage. The operators should
equipment damage. take frequent rest breaks and cease
operations when they become tired or
High pressure fluid from hand held or hand distracted.
directed pressure and flow directing devices
may overpower an operator’s ability to Before the equipment is started, the work
control or direct the device, which could lead area must be inspected and properly
to personal injury, death and/or equipment prepared to avoid personal injury, death,
damage. The operator must brace against and/or damage to equipment. Make sure
the backward thrust of a hand held device. the work area is checked for hazardous
In addition, a safety harness or safety net fumes, has adequate ventilation for engine
must be used when working in an area exhaust and sufficient drainage for released
where the operator could be injured in a fall. fluid. Check the work area for electrical
Stand to the side of any tubing or container equipment, connections, outlets, fixtures, or
being sprayed to avoid back spray and lines. If any are present they must be made
never operate a hand held device above water tight and the electrical power to these
shoulder level. devices must be shut off to avoid electrical
shocks from fluid contact. The work area
Never direct the pressurized fluid stream at should be clearly marked and roped off to
yourself or any other person, control valves, keep unauthorized people and vehicles from
the pump, pump drive, suction or discharge entering. Remove all loose parts, tools and
systems. The pressurized stream can equipment from the work area before
cause serious personal injury or death and beginning operation.
can also change valve or control settings
which could dangerously increase the All pressure containing devices including
delivery pressure to the pressure and flow wands, nozzles, guns, hoses, connections,
directing device. etc., should be regularly checked for
condition. These components should all be
When operating a pressure and flow tagged with their tested pressure capabilities
directing device, use only equipment which together with the date testing was
automatically shuts off flow when an performed. Always be aware of the
operator releases hand or foot pressure on pressure level in the system and never
the pressurized flow trigger control to connect any equipment to the system
prevent injury if the operator is overpowered which has a rated or tested pressure
or becomes disabled. capability below the system operating
pressure. The equipment must be shut
Check to insure this automatic shut-off down and the system pressure released
equipment is operating properly before before changing or disconnecting wands,
every use and never circumvent the nozzles, guns, hoses, connections or any
automatic shut-off for any reason or by any other pressurized system components.
means when operating the equipment.
All pressure containing devices including
When operating any type of high pressure wands, nozzles, guns, connections, etc.,
liquid jetting, blasting or cleaning devices, plus all automatic shut-off, pressure and
the operators must always wear protective control equipment should be treated with
clothing including, but not limited to, a hard care. Protect them from damage by people,
hat with full face visor, heavy duty rain coat objects and vehicles. Never lay them in dirt,
and pants, boots with nonskid sole and mud, ice or other loose material which could
safety toe, rubber gloves with rough grip plug the fluid opening or interfere with their
surface and ear noise protection. operation. Never use the wand, nozzle,
gun, etc. to pry loose material off items
Full operator attention and alertness are being cleaned.
required when operating this equipment to
avoid personal injury, death and/or

Page 7
Before starting operation in a cold
environment, check to make sure there is no
ice in the fluid system and repeat this
inspection each time before operation is
restarted.

Before purchasing wands, nozzles, guns,

connections, hoses, etc., manufacturers of
these components should be contacted for
detailed information on the design and
safety features incorporated in their
products. After careful study of various
manufacturers products, we recommend
that only those wands, nozzles, guns,
connections and hose, etc., be considered
for purchase that you judge to offer the
highest quality of design, construction and
safety, since these components are among
the most critical to the safe operation of high
pressure liquid jetting, blasting and cleaning
equipment.

After you have selected and purchased

these components, follow the
manufacturer’s instructions completely in
their use.

In summary, high pressure jetting,

blasting and cleaning are inherently
dangerous, as the pressures and flow
rates needed to remove scale, clean, etc.
are sufficient to cause personal injury,
death, and/or equipment damage
resulting from, but not limited to, any of
the conditions described in the above
Danger Notices.

Page 8
SECTION 2
DESIGN, DESCRIPTION AND SPECIFICATIONS

INTRODUCTION

The Gardner Denver LC 1000 is 1000 Therefore, in the beginning of this manual
brake- horsepower, high rod load multi- the user is introduced to dangers inherent in
purpose pump for various applications such the operation of a high pressure pump. To
as oil and gas well fracturing and acidizing. avoid accidents and injuries, all safety rules
Other applications include coiled-tubing and listed in this section and also all other
hydro-blasting operations when supplied applicable safety rules and regulations must
with the Inline fluid end. The pump was be carefully observed.
designed using modern analytical and
engineering methods and techniques. The The sections on Pump Design, Description,
gear drive was designed in accordance with and Specifications, describe the pump
the most recent standards, procedures, and design, list the pump specifications, and
computer software developed by American present drawings depicting the pump
Gear Manufacturers Association. external views and all essential cross-
sectional drawings.
The issue of personnel safety is the most
important topic covered in this manual.

FIGURE 2-1 LC 1000 Pump

Page 9
Section 3, "Pump Preparation, Operation, bearings, and recommended fastener
and Maintenance," addresses the issues of torques.
preparing the pump for operation after
shipping or storage, the lubrication system PUMP DESIGN
design and specifications, the new pump
run-in procedures, and the periodic routine The LC 1000 pump uses three major
maintenance schedule. The recommended assemblies: power end, fluid end, and gear
oils, viscosity data, and crankcase oil reduction unit. The pump is designed with a
temperature requirements are also modular concept. Each assembly is a
presented in this section. module that can be assembled, handled,
installed, fixed, or transported separately
Section 4, "Service Procedures," describes from the rest of the pump (See FIGURE 2-1,
the various assembly / disassembly page 9). The following is a brief description
procedures. of the essential design features for each
modular assembly.
Section 5, “Trouble–Shooting,” describes
possible problems, causes and solutions POWER END (FIGURE 2-2,FIGURE 2-3)
related to pump performance.
The power end is a welded fabrication
Section 6, “Rebuilding Data, Recommended utilizing high-strength low-alloy frame
Running Clearances and Torques,” presents members, stress relieved and precison
information useful for pump rebuilding and machined to provide stability and strength.
assembly, including dimensional and The crankshaft is a one piece, forged alloy
tolerance data, running clearances for all steel, heat-treated and precision ground.

FIGURE 2-2 LC 1000 Power End

Page 10
 FIGURE 2-3 LC 1000 Power End Top View

oil-stop heads are light-weight aluminum to

NOTICE help reduce weight. The power end is a
dry-sump pump, which means that the
connecting rods do not “dip” into the oil for
The recommended direction of splash-cascade lubrication. The power end
rotation is clock-wise. However, must be supplied with lube oil from an
counter clock-wise rotation is external source, supplied by others. Large
allowable. drain openings are provided in the bottom
of the power end and reducer, and should
The crankshaft is supported by four main be connected to an external oil sump (see
roller bearings. The drive end of the lubrication section for more details). A
crankshaft is a male spline which mates with power end breather allows rapid
a female spline in the gear-reducer bull equalization of internal pressure in the
gear. The connecting rods are precision power end, as well as the gear reducer.
machined from high-strength alloy steel
castings. Connecting rod bearings are
automotive type, with round, grooved GEAR REDUCTION UNIT (FIGURE 2-4)
sleeve-bearings on the crosshead end.
Crossheads are machined from one piece The light weight, planetary style gear
high strength ductile iron castings. reducer unit is standard equipment. This
Precision machined replaceable crosshead 5.5:1 ratio reducer offers the best power to
guide shoes allow easy repair and power- weight ratio and input driver flexibility. The
end rebuild. The pony rods are steel with a installation and removal of the gear
hard metalized and ground surface. The reduction unit is easy and convenient due to

Page 11
a splined gear coupling between the bull- steel to ensure the highest reliability and
gear carrier and the pump crankshaft. All long life of the gear box. (The parallel shaft
gears are carburized, case hardened, heat gear reducer, which is 5.74:1 ratio, is
treated and precision made of aircraft quality available on special order.)

POWER END AND GEAR REDUCTION The gear reduction unit oil inlet connection
UNIT LUBE SYSTEM (FIGURE 2-2, is connected externally with the power end
FIGURE 2-3, and FIGURE 2-4,) oil supply. One connection supplies both.

Both the gear reduction unit and power end The lube oil is drained from the planetary
are connected to the same lube oil inlets. reduction unit from two 1” NPT drain holes,
The power end inlet is located toward the and each drain should be piped back
rear of the pump. The inlet is a 1/2” NPTF individually to the external oil sump with
which divides the lube flow between the lube minimum restrictions. A scavaging pump is
manifold for the crosshead guide and the preferred, to evacuate the reducer. It is
rotary union. Pressurized lubrication for important that the oil sump drain hose sizes
each crosshead is delivered from the lube be maintained to the primary external sump
manifold through the underside of the and include as few restrictions and direction
crosshead guide. An aluminum cover changes as is practical. Gear unit heating
houses the rotary union, which is attached problems are most often related to drain
to the crankshaft. Lubrication for the power restrictions causing buildup of oil inside the
end components comes from forced lube unit, thus generating excessive heat.
through the crankshaft. Lube oil enters the
crankshaft and first lubricates the #4 main Restrictions in oil flow / oil pressure to the
bearing. Oil from the main bearing also planetary may be required if the reducer
lubes the thrust bearing. As oil reaches the does not adequately drain. Check new
first crankshaft journal, oil exits the journal installations for overheating of the reducer.
oil hole and lubes the journal and journal
bearings, passes through the center of the
connecting rod to the wrist pin and bushing. NOTICE
The slides supply oil to the crossheads. This
is repeated for the rest of the main bearing It is also extremely important to
cylinder components. Oil is removed from maintain some downward slope in
the power end through two (2) 3-1/2” o.d.
drains in the bottom of the frame near the
the entire drain system back to the
rear of the power end. lube reservoir or external sump.

FIGURE 2-4 LC 1000 Planetary Gear Reducer (5.5:1 Ratio)

Page 12
FLUID END (FIGURE 2-5) intersections. Wing guided type valves and
seats with replaceable inserts are standard.
Three basic fluid end styles are offered on The one piece plungers are precision
the LC 1000. The standard fluid end is the ground and polished hard overlayed steel.
H/V (Horizontal Valve) Monoblock, or one The stuffing boxes are replaceable alloy
piece fluid end. (Optional styles include steel for ease of maintenance and repair.
Valve-Over-Valve fluid ends and Inline fluid Standard flanges include one Fig.1502 or
ends). Fig. 1002 series discharge flange and one
blanking flange. The suction manifold is a
The standard H/V Monoblock configuration 5” pipe with a victaulic connection on the
is shown in Figure 2-5. The Monoblock inlet. Other size suction manifolds are
features a one piece, heat-treated forged available as optional equipment.
alloy steel block, precision machined with
hand ground and polished radii at all bore

FIGURE 2-5 LC 1000 H/V Fluid End

Page 13
 GENERAL SPECIFICATIONS

This section presents the pump basic specifications. The first set of specifications deals with the
pump's power, rod load, plunger stroke, and overall dimensions. The other table presents
allowable pressures and flows for various pump speeds along with data on power requirement.

LC 1200A PERFORMANCE RATING

Rated Brake Horsepower 1200 bhp

Stroke Length 6.0 inches

Maximum Rod Load 200,000 pounds

Gear Box Ratio 5.5 : 1

Overall Length 85 inches

Overall Width 65 inches

Overall Height 34 inches

Weight (system dry) 7,650 pounds

LC 1000 PERFORMANCE RATING

Rated Brake Horsepower 1000 bhp

Stroke Length 6.0 inches

Maximum Rod Load 175,000 pounds

Gear Box Ratio 5.5 : 1

Overall Length 85 inches

Overall Width 65 inches

Overall Height 34 inches

Weight (system dry) 7,650 pounds

Page 14
SECTION 3
PREPARATION, OPERATION AND MAINTENANCE

6. Coat the gear reducer input shaft and

all extension rods with a heavy rust
DANGER preventive.

Read and understand clearly all 7. Plug drain holes at the bottom of the
pump frame, and the bottom of the
safety rules and precautions before
planetary gear reducer, and plug
attempting to operate the pump. inlets.

This section deals with pump preparation 8. Store the pump inside in a warm dry
after shipping and storage of the pump, user place.
built lubrication system and its
specifications, pump break in procedures, 9. If the pump is shipped ocean cargo, it
recommended oils, allowable crankcase must be crated in a water-tight contain-
operating tempera-tures, viscosity er placed below the deck to prevent
conversion tables, and routine maintenance rusting and salt water contamination.
schedule.
PUMP MOUNTING INSTRUCTIONS
PREPARATION AFTER SHIPPING AND
STORAGE Follow this procedure to shim the feet of the
pump. This will require the use of four
All pumps are shipped dry and therefore Grade 8, 1” hex-head screws with lock
must be flushed with light weight oil before washers and nuts to secure the rear feet.
operating. The flushing must be performed The front feet will require four ¾” grade 8
regardless of method or duration of the cap screws with large-diameter ¾” flat
shipment or type of container the pump was washers for the shock-rubber mounts. The
shipped in. fluid end is supported by the power end
frame.
Pumps are not prepared for storage and
should be put in service as soon as 1. Set the pump in its location.
possible.
2. Install one ¾” bolt with flat washer in
If for any reason the pump has to be put into the two feet at the front of the power
storage after prior use, the following frame. Snug but do not over-tighten.
procedure should be followed:
3. Be sure all suction and discharge
1. Clean and flush the fluid end with a rust piping connections are dis-connected
preventative. to allow free movement of the fluid end.

2. Plug all discharge and suction 4. Using a feeler gauge, check under the
openings. rear feet. Both feet must be in firm
contact with support bracket or skid.
3. Drain oil from the power end and the
gear reduction unit. 5. Select the proper number and
thickness of shims to fill the gap under
4. Flush the power end with a rust the high foot, if a gap is found.
preventative (before flushing make sure
that the rust preventative will not clog 6. With shims in place (if required), install
the oil passages). bolts in the remaining power frame
mounting feet. Use appropriate torque
5. Remove the breather and either plug or for rear feet. (See Torque, pg. 34.)
tape the opening.

Page 15
7. Front shock-mounts should be snug, The following guidelines, developed as a
but do not over-tighten and extrude result of long experience, should be adhered
rubber mount. Use Loctite on Nuts. to closely. The external, customer furnished
oil sump should be a minimum 50 gallon
8. Connect the suction line to the inlet of capacity. Use drains from Reducer to sump
the suction manifold, making sure that and power end to sump, not common
no strain is placed on the suction drains.
manifold. 1. The oil flow velocity through the suc-
tion piping should not exceed 2 ft/sec.
9. Connect the discharge line with high-
pressure hose or high-pressure pipe 2. At maximum operating speed the
utilizing swivel joints to allow vacuum reading at the lube pump inlet
movement between the pump and the must be no more than 8" hg or 4 psi or
sub-base supporting the discharge line. 0.28 bar.

10. Vibration isolation connections or tie- 3. The suction strainer should be sized for
downs for the discharge lines are oil flow three (3) times larger than the
recommended to help reduce actual flow passing through the
vibrations. strainer.

POWER END LUBRICATION SYSTEM 4. The suction lines should be kept as

short as possible and free of bends.
Due to variety of applications and drive
arrangements, the power end lubrication 6. Warning devices to monitor lube oil
pump and applicable auxiliary hydraulic pressure and temperatures are highly
equipment are not furnished with the triplex recommended. The triplex pump
pump. Therefore, the pump lubrication operates at very high rod loads and
system is designed and built by individual pressures, and malfunction of the lube
customers for each particular application. system may result in serious damage
occurring in a very time. Therefore,
The lubrication system is very critical to the early warning devices are essential to
triplex pump performance and therefore the successful operation and should be
should be professionally designed in set according to the following operating
accordance with sound engineering limits:
practices developed for similar systems,
known otherwise as hydraulic power units or
HPU. The following discussion will re- NOTICE
emphasize some of the good practices used
in designing similar systems in the past and MAXIMUM lube system pressure
comment on the system’s critical
should be set at 120 psi (relief
components.
valve setting.)
Lube System Pump
MINIMUM lube pressure : 40 psi.
A positive displacement pump must be Normal HighTemp: 150 F.
used. Gear type pumps have demonstrated Max. Operating Temp: 180 F.
reliable performance for similar applications
in the past. The pump should have the MINIMUM lube flow is 20 gpm.
largest suction port available for the Approximate flow is 3 to 4 gpm to
selected pump size to minimize losses in the
gear reducer and 16 to17 gpm to
suction piping.
power end. Design: 30 gpm.
Lube Pump Suction Piping Sizing and
Requirements (See also page 12) Max. lube system vacuum at lube
pump inlet 8 Hg.( 4 psi /0.28 bar)

Page 16
 FIGURE 3-1 Lubricant Recommendations

FIGURE 3-1 indicates API-GL5 oil grades PLUNGER / PACKING LUBRICATION

recommended for use in the pump power
end and the gear reducer lube system. The fluid end plungers are lubricated from a
Crankcase operating temperature ranges separate lubrication pump through the
and minimum startup temperatures for stuffing box. The lubrication pump, hosing,
each listed grade of oil for various inlet and check valve to the stuffing box is not
or sump temperature ranges. provided with the unit.

See "Plunger Packing Lubrication

Recommendation Chart," page 20, for a list
of lubricants recommended for plunger
/packing lubrication.

Page 17
 quality assurance procedure. However, the
STARTUP AND NEW PUMP RUN-IN new pump break-in period process may
PROCEDURES continue for the first 80-100 hours of
operation, and therefore it will be each
A centrifugal charge pump will be required user’s responsibility to perform all the tasks
to charge the fluid end suction manifold. The related to this critical period. As all moving
charge pump should be sized according to parts of the pump go through wearing-in
the volume to be pumped by the triplex process, steel and bronze wear particles are
pump so that there is no less than 50 psi carried by the oil flow in the lubrication
charge when the triplex pump operates at its system. The resulting contamination of the
maximum flow. lubrication system with the wear particles
and especially clogging of the strainer and
The first startup and several hours of the the oil filter may cause serious problems. To
pump run-in are performed at the factory assist the user,
during the acceptance tests as a part of
the following guidelines are presented for 8. Start the plunger lube system and
the maintenance personnel to follow during check to see whether it is adjusted
the critical startup and break-in period: properly.

1. Fill the lube oil reservoir with 9. Run at low speed to "work out" any
recommended grade of oil. See "Power trapped air in the fluid cylinder with the
End Lubrication," and FIGURE 3-1, charge pump operating.
page 16.
10. Run the pump at 80-90 strokes per
2. Fill the packing lube reservoir with minute and 20% of its maximum
proper oil. See "Plunger/Packing pressure rating for 30 minutes
Lubrication Recommendation Chart,"
page 20. 11. During this time, observe the suction
vacuum gage reading, oil pressure and
3. Remove all inspection covers on the temperature and check for leaks.
top of the pump frame.
12. Run the pump at 80-90 strokes per min
4. Start the engine at the lowest possible at the following loads:
RPM and triplex pump at zero (0) 40% of full rated load 30 min
pressure. Make sure that all roller 60% of full rated load 30 min
bearings, crossheads, connecting rods 80% of full rated load 30 min
and crankshaft bearings are properly 100% of full rated load 30 min
lubricated.
13. During the operation observe the oil
5. Increase the engine RPM to maximum pressure and temperature, and inlet
and check whether the vacuum reading suction vacuum gage reading, and
at the lube pump suction inlet is less entire system for proper operation.
the 8" Hg or 4 psi or 0.28 bar.
14. If the triplex pump is equipped with a
6. Check whether the lube system transmission, run the pump for 30 min
pressure reading is at least 100 psi or in each gear in the higher gear ranges
7.0 bar. Temporary pressure gages pulling full horsepower in each gear.
should also be checked at this time to Observe closely oil pressures and
make sure that all components of the temperatures, and lube oil suction
lube system are working properly. vacuum.

7. Check to see that oil flow back to the 15. Shut the pump down and let it cool
reservoir is normal. (There should be thoroughly before starting normal
no accumulation in the power end.) operation of the pump.

Page 18
16. During the shutdown, change the oil 2. Periodically monitor lube oil operating
filter elements and clean the suction pressure and temperature. Minimum oil
strainer. operating pressure is 50 psi. The
maximum oil operating temperature
17. Change the lube oil and clean the depends on a particular grade of oil
reservoir to get rid of metal particles used in the pump lube system. (See
and any other wear products now FIGURE 3-1, page 17).
present in lube oil system.
3. Check the lube pump suction inlet
18. Change filter elements and clean vacuum. A vacuum gage reading
strainer every 10-15 hours, till it higher than 8" Hg or 4 psi or 0.28 bar
becomes apparent that wear-in process indicates that the suction strainer
is finished. and/or oil filter element are clogged.
The strainer must be cleaned, and the
19. Tighten all fluid cylinder attachment oil filter element replaced as
nuts, procedure listed in "Fluid End necessary as soon as the pump can be
Removal and Installation,” page 21, shut down for a short period of time to
after 50-70 hours of pump operation. perform these tasks.
See FIGURE 4-1, page 22.
4. Listen for any abnormal noise or rough
20. Change the lube oil again, replace the operation, which may indicate the need
filter elements, and clean the strainer for fluid end maintenance such as
after 80-100 hours of pump operation. changing valves or valve seats. Due to
very high pressures in the triplex pump
21. Follow the routine maintenance fluid end, worn valves and seats should
schedule described in the next section be changed as soon as possible to
after completion of the wear-in period. prevent washing them out with the
pumped fluid.
PERIODIC ROUTINE MAINTENANCE
SCHEDULE 5. Check the plunger/packing lubrication
pump for proper operation. Insure
Performance of the periodic routine packing nut is tightened sufficiently into
maintenance tasks, described in this stuffing box. Recheck tightness after
section, will ensure long, economical, and extended continuous operation.
trouble free operation of this pump. It is
highly recommended that the customer set
up a maintenance program during the run-in Monthly (100 hour) Routine Maintenance
period. The periodic maintenance data Tasks
should be recorded and kept with other
pump documents. The following 1. Clean the strainer and replace the oil
recommendations, based on previous filter element.
experience, should serve as a guideline for 2. Check the entire lube system for leaks
establishing a good maintenance program. and eliminate them.
The periodic maintenance schedule is
divided into daily, monthly, and quarterly 3. Check all fluid end expendables such
tasks to be performed by the user after the as valves, packings, and valve seats
pump has gone through 100 hours of wear- and replace them as necessary.
in period. For the tasks performed during the
wear-in period, see "Startup and New Pump 4. Check the extension rod seals and
Run-In Procedure," page 17. replace them as necessary.

Daily Routine Maintenance Tasks Quarterly (300 hour) Routine

Maintenance Tasks
1. Check the oil level in the lube oil
reservoir. 1. Change the lube oil and clean the oil
reservoir thoroughly.

Page 19
 7. Check all lube system warning and
2. Clean the lube system strainer and alarm devices for proper operation and
replace the oil filter elements. replace if found defective.

3. Re-tighten the critical bolt joints 8. Check supply of on hand expendables

following torque specifications given in such as packings, valves and seats,
Section 6. maintenance items such as seals, O-
rings, oil and breather filter elements,
4. Add grease to all exposed bare metal and also maintenance tools. Order to
to prevent corrosion. replenish supplies as necessary.

5. Clean or replace the breather cap filter The recommended routine periodic
element. maintenance procedures are very simple
and can be performed in a short period of
6. Check all pressure, temperature, and time. At the same time, close adherence to
vacuum gages for proper operation these procedures will ensure long,
and replace as necessary. economical, and trouble free operation of
the pump.

Page 20
 PLUNGER PACKING
LUBRICATION RECOMMENDATION CHART

ROCK DRILL LUBRICANTS - NORMAL CONDITIONS

Source Type Pour Point Maximum
Amoco Amoco Rock Drill Oil - Light -20 F
Amoco Rock Drill Oil - Medium 0F
Arco Air Drill #147 0F
Arco Trueslide #150 15 F
Chevron Oil U.S.A. Vistac #68X 10 F
Vistac #100X 5F
Vistac #150X 0F
Conoco EP Rockdrill #49, #17, #78 5F
Gulf Oil (Chevron) Rockdrill #100 -30 F
Rockdrill #32 -35 F
Exxon Arox EP #46 -20 F
Arox #150 -35 F
Mobil Oil Co. Almo #525 -20 F
Almo #527 -20 F
Almo #529 -10 F
Almo #532 0F
Pacer Oil Rockdrill #150 -10 F
Rockdrill #600 0F
Phillips Petroleum EP #500 (Summer) or EP #300 (Winter) -10 F
Shell Oil Co. Torcula Oil #32 -50 F
Torcula Oil #100 -20 F
Torcula Oil #150 -15 F
Torcula Oil #320 -10 F
Sun Oil Co. Rockdrill 500 (Light) 5F
Rockdrill 1000 (Heavy) 5F
Texaco Oil Co. Rockdrill Oil XL -40 F
Rockdrill Oil XM 0F
Rockdrill Oil XH -10 F
Union Oil of Ca. Marok 150 ------

STEAM CYLINDER OILS - HIGH TEMPERATURE PUMPED FLUIDS

Source Type
Amoco Amoco Cylinder Oil 460
Arco Modco Cylinder Oil 125, 175
Conoco Inca Cylinder Oil
Exxon Cylesstic TK-460 or TK-1000
Gulf Oil (Chevron) Senate #375 Compound
Security #460 Non-Compound
Mobil Oil Co. Mobil Cylinder Oil 600W
Pacer Oil Com-Cyl Oil
Phillips Petroleum Hector Cylinder Oil
Shell Oil Co. Valvata J-460
Sun Oil Co. Occident
Gear Oil 7-X, Gear Oil 8-C
Texaco Oil Co. Pinnacle Cylinder Oil

Page 21
SECTION 4
SERVICE PROCEDURES

This section describes various assembly FLUID END SERVICE

and disassembly procedures necessary for
pump servicing or parts replacement. The This discussion starts with the description of
General Requirements and Safety Rules steps necessary for removal and installation
section is a reminder for the maintenance of the fluid cylinder assembly and proceeds
personnel of the critical importance of safety to the removal and replacement of
rules and precautions while working on the expendable parts such as valves, valve
pump. Notes on dangers and notices seats, and packing.
specifically related to service procedures are
repeated and placed in this section also. Fluid End Removal and Installation

The pump consists of three major modules: 1. Disconnect suction manifold from unit
the fluid end, the power end, and the gear piping and discharge lines at the
reduction unit. (See Section 2) The discharge flanges on the fluid end,
description of service procedures follows the plunger lubrication lines, and also any
modular concept. Due to many expendable accessories such as stroke counters,
parts, fluid end servicing is rather common pressure gages, etc. from the fluid end
in the field and is therefore presented in the
very beginning followed by power end and 2. Remove all three (3) Suction Valve
gear reduction unit servicing procedures. Carriers, using the special hex wrench
on the S. V. C. hex. By hand, reach in
General Requirements and Safety Rules and remove the suction valve stops.

3. Unscrew and remove all three plungers

with the plunger removal tool furnished
DANGER with the pump. (Loosening the stuffing
boxes may be helpful on newly packed
Before any attempt to work on pumps pumps.)
is made, all safety rules and
4. Connect a hoist to the fluid end and
precautions described in this manual tighten the slings until they are snug
must be read and clearly understood. only. Make sure that hoisting slings are
not too tight, because that may cause a
strain on the 1-5/8” studs and damage
threads when removing from the pump
frame.
DANGER
5. Remove all twelve (12) 1-5/8" Heavy-
Only qualified and specially trained hex nuts located inside the pump
personnel should be allowed to work cradle chamber, utilizing either a
hammer wrench, large socket wrench,
on this pump.
or hydraulic torque wrench.

6. Note the two top-outside studs are pilot

studs, and are a tight fit. Pull the fluid
end assembly in a horizontal direction,
DANGER straight away from the power end until
it is completely free from the 1-5/8”
Proper capacity hoist and lifting studs.
devices should be used while
working on pump. 7. Move the fluid end to the service area
for changing valves or other service.

Page 22
 4. Remove the packing nut and place on
NOTICE a work table.

The procedure for fluid end 5. Remove all packing and brass from the
stuffing box bore.
installation is presented separately
due to the alignment and critical 6. Before repacking the pump, check the
nature of the connection between the plunger, brass, and stuffing box bore
power end and the fluid end. for excessive wear or damage.

7 Install packing and brass in the stuffing

To reinstall the fluid end proceed as follows: box with the packing lips facing the
valves area. (see FIGURE 4).
1. Check all twelve 1-5/8” studs for thread
damage. If replacement is required, 8. Clean and Anti-Seize the stuffing box
refer to the Parts List section to order and packing nut threads, and screw the
the proper stud for the fluid end. packing nut in hand-tight only.

2. The two outside upper studs are special 9. Slide the plunger thru the cylinder and
pilot or alignment studs. See parts list the stuffing box, making up tight
for proper replacements. against the crosshead.

3. Clean all studs and threads thoroughly, 10. Install the suction valve stop.
along with the holes in the power
frame, the nose plate, and the fluid 11. Tighten the stuffing box with the tool
cylinder. provided with the pump.

4. Lubricate the 1-5/8” stud threads with 12. Replace the SVC (Suction Valve
Never-Seize, Dow-Corning 1000 anti- Carrier) high-pressure seal if damaged.
seize or equivalent. Install the heavy-
hex nuts by hand. 13. Check the suction valve and seat, and
replaced as required.
5. Using a hand-held torque wrench, or
hydraulic torque tensioning tool, torque 14. Use grease to hold the Suction Valve in
all 12 nuts to 2300 ft. lbs. lubricated. place on the SVC. (Silicone may be
required to hold the valve spring).
6. Re-install the plungers, piping
connections and auxiliary equipment. 15. The SVC MUST be maintained tight
during operation to prevent seal
Plunger and Packing Replacement leakage, as well as thread fatigue.
The suction covers should be hand
This service procedure can be performed tightened metal-to-metal using the
with the fluid cylinder in place on the pump, hammer wrench as a simple hand
and consists of the following steps: wrench. Then the suction valve
carrier is marked, along with a mark
1. Remove the Suction Valve Cover with on the fluid cylinder, the cover should
the appropriate tool (see parts list). then be tightened another 3/8”. This
is accomplished using the hammer
2. Remove the suction valve stop by wrench provided with the pump and a
hand. The plunger is now exposed. 10 pound sledge hammer.

3. Loosen the packing nut and unscrew 16. Re-connect the lube lines.
the plunger, using the plunger
removeal tool. Remove the plunger
through the front of the fluid end.

Page 23
 This procedure may be performed with the
fluid end on the pump.
Stuffing Box Replacement

This procedure is to be performed if it is

determined that the stuffing box must be WARNING
changed because of seal leaks or damage.
Never try to remove or cut a valve
1. (Removal of the fluid end is
recommended when changing the
seat with a torch. Severe damage to
stuffing box or stuffing box seal.) the fluid end may occur.

2. Be sure to remove the plunger

lubrication lines from the stuffing box. Before starting, make sure that special tools
required for this procedure are available. For
3. Support the stuffing box using a nylon part numbers of the tools see the Parts
sling attached to a hoist, or a thin metal Manual.
band when removing from pump.

4. Loosen the stuffing box using the 1. Remove the discharge valve cover with
stuffing box removal wrench. the tool provide with the pump, or a 10
pound sledge on the hammer lugs.
5. Carefully remove the stuffing box from
the cradle area by lifting up with the 2. You should now be able to remove the
sling or metal band. discharge valve and spring by hand.

6. Clean and oil the packing bore in the 3. Remove the Suction Valve Cover(SVC)
stuffing box. Clean or replace seal. taking care not to damage seals.
7. Install the stuffing box seal, lubricating
with a light coat of grease. 4. Remove the suction valve and spring.
8. Complete packing installation by
following steps 5 thru 7 of the “Plunger
and Packing Replacement” section on 5. Remove the suction valve stop by
page 22. hand. (Tap with hammer if it appears
stuck.)
9. Lubricate the stuffing box threads with
Dow-Corning 1000 anti-seize or 6. Remove the suction valve seat and
equivalent. discharge valve seat with a seat puller
and a seat puller jack. These tools are
10. Install sling on stuffing box and position available from Gardner Denver.
to install in the fluid end.
7. Clean the valve seat decks thoroughly.
11. Install and tighten the stuffing box in
the fluid end. (Note: The stuffing box 8. Be sure the O-ring is installed on the
will “bottom out” in the fluid end bore seat and snap the valve seat into the
when tightened properly.) taper by hand to fit tightly.

12. Repeat this procedure for each 9. Place the winged valve on the top of
the valve seat.
cylinder.
10. Bump the seat into the taper 2-3 times
Valve and Seat Replacement with a heavy bar to make they fit tight.

Page 24
11. Reinstall the discharge valve and 4. Check the following at reassembly:
spring, and suction valve stop. (a) bearings and crankshaft must be
clean and have at least a 16 RMS
12. Install new seals for the discharge finish, (b) match-marks line up and
cover and reinstall the cover. dowel pins are in place, (c) the rod
bearing is free on the crankshaft, and
13. To install suction valve and SVC, see will slide back and forth.
the Plunger and Packing Replacement
section, steps 12 thru 15. TO REPLACE CROSSHEAD AND
SLIDES:
14. Run the pump at 80%maximum
discharge pressure, or until valve 1. Steps 1 thru 3 above.
seats “pop” and seat in the fluid end.
2. Remove writs pin retaining plate.
POWER END SERVICE
3. Remove wrist pin using slide hammer.

4. Roll pump until con rod is free of

DANGER crosshead, and roll crosshead out side
of pump.
Before attempting to service the
power end of the pump, the following 5. Remove connecting rod out rear of
pump.
safety precautions must be observed:
1. Shift the pump transmission into 6. Remove crosshead slide bolts and
the neutral gear. slides. (Disconnect lube lines to slides.)
2. Shut off the pump engine and 7. Replace slides, roll crosshead into place
remove the key from the ignition from the side, and check clearance
to prevent starting the engine between crossheads and the slides.
inadvertently. The diametrical clearance should be
0.010” to 0.016”.

The power end service procedures deal first 8. If clearance is less than 0.010”, replace
with major assemblies, namely connecting the crosshead or slides, or lap to size.
rods, crossheads, crankshaft, and gear
reducer assemblies and then describe how 9. If the clearance is more than 0.016”, add
to access all individual parts. shim stock between the slide and main
frame to obtain the 0.010" to
TO REPLACE A ROD BEARING: 0.016"clearance.

1. Disconnect the pump drive and 10. Use Spherical Washers (300FWD244)
remove the side and rear covers. on slide screws. Loctite screws. Torque
to values shown on Torque Chart.
2. Remove the rod cap. The rod and
cap are match-marked for correct 11. Re-connect the slide lube lines.
reassembly, with two dowel pins to
align these halves. 12. The connecting rod with its bearing
cap, crankshaft bearing, crosshead
3. With a rubber hammer or wooden bushing, and crosshead pin and
hammer handle, tap on the edge of crosshead should stay together as a
the bearing to remove it. set.

Page 25
 FIGURE 4-3 Crosshead Assembly

13. The clearance between the connecting side light-weight cover must be removed
rod bushing and the crosshead pin and the counter-weight moved to the
should be 0.002” to 0.006”. vertical position. The gear reducer
output female spline will have a mark to
14. If the clearance is more than 0.008” locate the internal reducer counter-
replace the bushing and/or wrist pin. weight. This should be located down -
or opposite - the off-side counterweight
TO REPLACE GEAR REDUCER: when installing on the crankshaft male
spline. (The left hand counter-weight
1. It is recommended that the gear should be located 180 opposite the
reducer be removed as a unit. right hand counter-weight.)
7. Install the new gear reducer to the main
2. Remove the pump from its mounting.
frame on the splined end of the
3. Support the gear reducer with an
crankshaft. Add enough gasket material
overhead lift.
between the main frame and the gear
reducer to insure free rotatin of the
4. Disconnect one internal oil line, and crankshaft when the reducer is
the external oil and drain lines. tightened in place. (The end main-
Remove the twelve 1” hvy hex nuts. bearing will be end-loaded if insufficient
gaskets are used).
5. Using the jack-screw holes, slowly
remove the gear reducer assembly. 8. Re-connect the gear reduce lube lines.
9. Rotate the power end slowly, and check
6. Units that have a counter-balance on to see that all parts are operating and
the off-gear reducer side also have a oiling properly, before replacing covers.
counter-balanced gear reducer. When
re-installing the gear reducer, the off-

Page 26
TO REPLACE CRANKSHAFT AND MAIN crankshaft is secured the the one held
BEARINGS: bearing.
12. Install the ourter race retaining ring on
1. Remove the gear reducer as described
the held center main bearing.
above.
13. Bolt the outer race bearing retainers to
2. Remove the connecting rods and
the main frame to secure the two center
crossheads as described in “TO
bearing outer races in place. A varing
REPLACE CROSSHEADS AND
amount of shim stock will have to be
SLIDES.”
placed between each retainer and the
3. Remove the end main bearing housing main frame. Allow approximately a
(disconnect the internal oil line) and 0.005” squeeze on each race when the
inside main bearing retainers from the capscrews are tight.
main frame. (For counter-weighted
14. After the bearing retainers are in place,
units, the off-drive counter-weight must
rotate the pump to check for free
be removed from the crankshaft.)
rotation.
4. One bearing is a held bearing. With the
15. Install the end bearing housing on the
bearing retainers removed, the
main frame. Add enough gasket
crankshaft is now free to SLIDE OUT
material between the main frame and
OF THE FRAME (toward the splined-
the housing to insure no end-loading of
end). USE CAUTION TO PREVENT
the outside main bearing.
INJURY. Use special crankshaft
handling tool and overhead lift. 16. Rotate the power end slowly and check
to see that all parts are free.
5. Bearings and races are now exposed
for removal. Using a torch, rapidly heat 17. Install the connecting rods and
the bearings one at a time and remove crosshead as described earlier in this
from the main shaft. section.
6. The bearings and races will have to be GEAR REDUCER:
driven from the main-frame using an
aluminum or brass bar and hammer. 1. See TO REPLACE GEAR REDUCER
to remove reducer from pump.
7. The bearings can be removed from from
the aluminum housing by first blocking 2. The planetary gear reducer should
up the housing, then heating the not be disassembled in the field. If
housing with a torch and allow the repairs are needed, the gear reducer
bearing to drop out the bottom. should be returned to the factory for
8. NOTE THAT one of the bearings is a repairs.
held bearing, and should be installed on 3. If the gear reducer is removed from
the crankshaft next to the splined end. the pump, see “TO REPLACE GEAR
9. Uniformly heat the bearing races to REDUCER” above if the pump has an
place on the crankshaft. Bolt the inner off-drive counter-weight, as the
race bearing retainers to the crankshaft location of the off-drive counter-
to secure the two center bearing inner weight in relationship to the gear
races in place. reducer counter-weight is important.

10. Chill the outer races prior to installation

in the main frame. Use caution when WARNING
installing the held bearing outer race,
making sure to locate it on the gear-
reducer side of the pump, opening Do not drive against rollers or
facing OUT toward the gear reducer. bearing cage. Drive only against the
11. Insert the crankshaft into the main bearing race, as severe damage to
frame. The axial position of the the bearings could occur.

Page 27
SECTION 5
TROUBLE-SHOOTING

PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Pump Overloads Driver. 1. Excessive pump speed 1. Reduce pump speed and/or
and/or discharge pressure. pressure.

2. Blockage or closed 2. Clean or open valve.

valve in discharge line.

3. Incorrect plunger size. 3. Install the correct

plunger.

4. Improper bypass conditions. 4. See recommended system

layout, and correct error.

Fluid Not Delivered. 1. Pump not primed. 1. Prime pump.

2. Air or vapor pocket in 2. Remove pocket from line.

suction line.

3. Clogged suction line. 3. Clean out line.

4. Suction and/or discharge 4. Remove the obstruction.

valves propped open.

Low Discharge Pressure. 1. Worn or fluid cut valve. 1. Replace valve assembly.

2. Valve propped open. 2. Remove the obstruction.

3. Pump cavitating. 3. See Cavitation, Fluid Knock

or Hammer problem.

4. Fluid leakage. 4. Replace plungers/packing

and/or fluid end seals.

5. Erroneous gauge reading. 5. Recalibrate or replace

gauge(s).

Low Suction Pressure. 1. Low head (NPSH). 1. Raise fluid supply level.
Install charging pump.

2. Insufficient charging pump 2. Increase charging pump

capacity. speed or size.

3. Retarded fluid flow. 3. Remove restrictions

from suction line.

4. Erroneous gauge reading. 4. Recalibrate or replace

gauge(s).

Page 28
PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Cavitation, Fluid Knock 1. Improper suction system 1. See recommended system

or Hammer. layout. layout in manual.

2. Low suction pressure. 2. See Low Suction Pressure

problem.

3. Suction stabilizer and 3. Install suction stabilizer

pulsation damper not used. and pulsation damper.

4. Defective stabilizer or 4. Repair and recharge or

damper. replace.

5. High fluid temperature or 5. Reduce pump speed.

viscosity.

6. High fluid vapor pressure. 6. Increase NPSH.

7. High acceleration head. 7. Increase supply line size.

Decrease supply line length.

8. Suction valve spring too stiff. 8. Use weaker spring.

with low NPSH.

9. Air/Gas in pumped fluid. 9. Allow more settling

time in supply tank.
Reduce pump speed.

10. Air entering suction line. 10. Repair suction line.

11. Air entering charging pump. 11. Tighten or replace shaft

packing or seal.

12. Air entering or charge gas 12. Repair and recharge

escaping from suction stabilizer
stabilizer.

13. Multiple pumps operating in 13. Use a suction stabilizer

phase. on each pump. Separate
lines may also be needed.

Suction or Discharge Line 1. Line(s) not supported. 1. Install supports or

Vibration. hangers.

2. Pump cavitating. 2. See Cavitation, Fluid Knock

or Hammer problem.

High Crankcase Oil 1. High ambient temperature. 1. Use an oil heat exchanger
Temperature. with a circulating pump.

2. Improper type/grade oil used. 2. Use recommended oil.

3. Pump overloaded. 3. Reduce pump speed and/or

pressure.

4. Improper clearance in main 4. Check and adjust clearance.

or rod bearings, crossheads Replace parts as required.
or bushings.

Page 29
PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Knock In Power End. 1. Improper main bearing 1. Check and adjust

clearance. clearances.

2. Incorrect pump rotation. 2. Reverse rotation.

3. Loose plunger coupling. 3. Check and tighten. Replace

if damaged.

4. Loose bearing housings/ 4. Check and tighten.

covers. Replace if damaged.

5. Worn crosshead pin. 5. Replace.

6. Worn crosshead pin bushing. 6. Replace.

7. Worn connecting rod to 7. Replace.

journal bearing.

8. Worn crankshaft. 8. Replace.

9. Worn crosshead. 9. Replace.

10. Worn main bearing. 10. Replace.

11. Valve noise transmitted to 11. See Excessive Valve

power end. Noise problem.

12. Cavitation noise transmitted 12. See Cavitation, Fluid

to or causing shock loading in Knock or Hammer problem.
power end.

Excessive Valve Noise. 1. Pump cavitation. 1. See Cavitation, Fluid Knock

or Hammer problem.

2. Seal on inserted valve 2. Replaced seal or valve.

damaged or missing.

3. Broken/weak valve spring(s) 3. Replace spring(s).

Oil Leakage From 1. Worn, damaged or corroded. 1. Replace extension rod.

Stop Head. extension rod.

2. Worn oil stop head seal. 2. Replace seal.

3. Oil level too high. 3. Reduce oil level.

4. Excessive crosshead wear. 4. Replace crosshead.

5. Pressure in crankcase. 5. Clean or replace air breather.

6. Misalignment in front. 6. Loosen bolts and center.

crosshead guide cover.

Page 30
PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Oil Seal Leakage. 1. Worn sealing lip. 1. Replace seal.

2. Damaged sealing lip. 2. Replace seal.

3. Outside diameter not seated. 3. Clean and polish bore of

oil seal housing.

4. Shaft rough at seal lip. 4. Clean and polish shaft or

replace wear sleeve.

5. Pressure in crankcase. 5. Clean or replace air breather.

Stuffing Box Leakage. 1. Short plunger/packing life. 1. See Short plunger/Packing

Life problem.

2. Worn packing rings/metal. 2. Replace packing rings/metal.

3. Seal leaking at fluid 3. Check seal, stuffing box

end. groove and sealing surface.

4. Corrosion due to wrong 4. Determine and install correct

stuffing box material stuffing box.
for pumped fluid.

5. Stuffing box bore worn. 5. Replace stuffing box.

Pumped Fluid In 1. Worn, damaged or corroded 1. Replace extension rod.

Crankcase. extension rod.

2. Worn oil stop head seal. 2. Replace seal.

3. Stuffing box leakage. 3. See Stuffing Box Leakage

problem.

Short Valve Life. 1. Abrasives in pumped fluid. 1. Filter pumped product.

Use severe duty valves
with insert.

2. Valve not sealing. 2. Broken valve spring - replace.

Worn valve guide - replace.
Worn valve/seat - replace.

3. Pump cavitating. 3. See Cavitation, Fluid Knock or

Hammer problem.

4. Corrosion. 4. Treat pumped fluid.

Use different materials
for valves/seats.
Install sacrificial anodes
in suction manifold.

Page 31
PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Short Plunger/Packing Life. 1. Abrasives in pumped fluid. 1. Consult Gardner Denver

Customer Service for plunger /
packing recommendation.
Filter pumped fluid.

2. Excessive plunger/packing 2. Lubricate with rock drill oil.

friction. Do not overtighten adjust-
able packing.
Use Gardner Denver plungers.

3. Metal parts or particles 3. Check stuffing box

wearing plunger. alignment.
Check gland alignment.
Check plunger alignment.
Check packing for foreign
particles.
Replace lantern ring.

4. Wrong plunger/packing for 4. Consult Gardner Denver

pumping conditions. Customer Service.

5. Wrong size packing. 5. Install correct size packing.

6. Improper packing installation. 6. Check installation procedure

and install correctly.

7. Excessive crosshead wear. 7. Replace crosshead.

8. Pump cavitating. 8. See Cavitation, Fluid Knock

or Hammer problem.

Catastrophic Failures: 1. Pump overloaded. 1. Reduce pump speed and/or

Broken Shafts, pressure.
Bent Rods, etc.
2. Start-up against closed 2. Insure valve is open
discharge valve. before starting.

3. Main bearing failure. 3. Repair or replace.

4. Plunger striking valve or 4. Check valve condition and

valve parts. installation procedure.

5. Plunger striking cylinder. 5. Check plunger for proper

length.

6. Frozen fluid in cylinder. 6. Do not start pump when

pumped fluid is below freezing
temperature.

7. Lube oil pump failure. 7. Replace oil pump.

Page 32
PROBLEM POSSIBLE CAUSE SUGGESTED ACTION

Catastrophic Failures: 8. Low oil level in sump. 1. Check oil level frequently,
Broken Shafts, and add oil as required.
Bent Rods, etc.
(continued). 9. Contaminated oil in sump. 9. Check oil condition
frequently.

10. Cavitation shock loading. 10. See Cavitation, Fluid Knock

or Hammer problem.

Stud Failures. 1. Catastrophic failures. 1. See Catastrophic Failures

problem.

2. Improper nut torquing. 2. Check torque specifications

and torque to correct values.

3. Stud bending due to uneven 3. Check nut seat surface for

nut seating. flatness. Rework or replace
as required.

4. Corrosive attack by pumped 4. Treat fluid or use corrosion

fluid. resistant studs.

5. Studs damaged before 5. Check condition before

installation. installation, and replace if
necessary.

6. Low strength studs. 6. Use Gardner Denver studs.

Page 33
SECTION 6
REBUILDING DATA, RECOMMENDED RUNNING CLEARANCES AND
TORQUES

REBUILDING DATA FOR LC 1000 PUMP (in.)

PUMP STROKE 6 Inches

Crankshaft Throw Diameter................................................. 7.4995” / 7.4985”

Crankshaft Shaft Diameter at Main Bearing ........................ 13.5039/13.5025 & 11.5034/11.5022

Distance Between Main Bearing Centers............................ 11”

Bore in Frame for Inner Main Bearings................................ 17.9980”/17.9995”

Bore in Hsng. & G.R. for Outer Main Bearings .................. 15.2482”/15.2496”

Connecting Rod Centers ..................................................... 11”

Connecting Rod Bearing Bore ……………………………….7.506” / 7.509”

Crosshead Guide Bore…………………………………………13.025” /13.029”

Crosshead............................................................................ 11.000”/10.998”

Wristpin ................................................................................ 5.001” / 5.000”

Wristpin Bushing Bore ......................................................... 5.009” / 5.010”

RECOMMENDED RUNNING CLEARANCES – ACTUAL

New (in.) Maximum Allowable

Wear Limit (in.)

Connecting Rod Bearing to Crankshaft ............................... .007”/.011” .................... .016“

Main Bearing Installed Clearance* ...................................... .0000”/.0063” ................ .012”

Crosshead to Guide*............................................................ .010”/.016” .................... .045”

Crankshaft Endplay.............................................................. .005”/.015” .................... .030”

Wrist-Pin-to-Bearing Clearance………………………………..007”/.010”……………….023”

* Feeler gauge clearances .001 inch less than actual values.

Page 34
 LC 1000

TORQUES
TORQUE WITH .
DESCRIPTION FASTENER LOCTITE ANTISEIZE

Crankshaft Bearing Retainers.............................. 3/8” – 16 19 -

Power End Covers…………………………………..3/8” – 16 16

............................................................................. 1/2 ”- 13 45

Crosshead Guide to Frame (Gr. 8) ..................... 5/8” – 11 90 -

Conn Rod Thru-bolts............................................ 3/4” – 10 150

Front Mounting Feet…………………………………3/4” – 10 150

............................................................................. 7/8 - 9 315

Gear Reducer to Frame Nuts……………………… 1” - 8 350

Plunger / Pony Rod to Crosshead (Old Style) ..... 1” - 8 475

Discharge Flange Studs / Nuts……………………. 1” - 8 475

Pump Feet Mounting Bolts, Rear Feet…………….. 1” - 8 545

Counter Weight to Crankshaft (Gr. 8)…………….. 1” - 8 550 -

Grade B-7 Studs .................................................. 1-1/8”- 7 675

Plunger / Pony Rod to Crosshead (New Style) ... 1-1/4”- 7 650

............................................................................. 1-3/8”- 8 1080

Counter Weight to Crankshaft (Gr. 8)…………… 1-1/2”- 6 1900 -

Fluid End to Frame Studs / Nuts.......................... 1-5/8”- 8 2300

............................................................................. 1-3/4”- 8 2400

Page 35