OPERATING INSTRUCTIONS AND
MAINTENANCE SUGGESTIONS FOR
ALL GASO DUPLEX PISTON POWER PUMP MODELS.
FOLLOW THESE
INSTRUCTIONS CAREFULLY AND YOU WILL HELP INSURE TROUBLE FREE OPERATION FOR THE
LIFE OF YOUR PUMP.
GENERAL PRECAUTIONS PRIOR TO STARTING PUMP
1.
Level pump to insure proper lubrication during operation.
2. Verify that pump
crankcase has been filled with the proper amount of lubricant.
3. Verify that
packing has been properly installed in the pump and is properly tightened.
4.
Tighten all stud nuts and cap screws to the recommended torque values.
5.
Squirt a light oil or other lubricant on the piston rods and rotate pump by hand
to verify free rotation.
6. When force-feed lubrication is used, verify that
the lubricator is filled and is operating properly.
7. Flush all suction lines
leading to the pump. This will help protect valves and seats from damage.
8.
For piston and packing protection, always prime pump.
This is a positive displacement
pump and is not intended to operate dry. This pump is designed to operate in a
cavitation-free system.
9. Verify that all valves in discharge piping are open.
WARNING: AN OPERATIONAL SAFETY RELIEF VALVE MUST BE INSTALLED IN THE
DISCHARGE LINE BETWEEN PUMP AND ANY OTHER PIPE FITTINGS. THIS RELIEF VALVE MUST
BE SET AT THE RECOMMENDED RELIEF PRESSURE DESIGNATED ON THE PUMP APPLICATION TAG.
WARNING:
CATASTROPHIC DESTRUCTION OF PUMP, PIPING, OR PERSONAL INJURY MAY RESULT IF DISCHARGE
LINES ARE CLOSED WHEN THE PUMP IS STARTED, OR AFTER THE PUMP IS RUNNING.
GASO
DUPLEX PISTON POWER PUMPS POWER END
LUBRICATION -
Gears,
connecting rod bearings and crossheads in all geared piston type pumps are lubricated
by splash from lubricant in the crankcase. Crankshaft bearings and pinion shaft
bearings in series 1800, 1500, 1600, 1700, 1900, and 2600 pumps are also lubricated
from this same oil in the crankcase by splash. Shaft bearings in Series 1550-C,
1654-C, 2000 and 2200 pumps and in pumps with Serial Number 24523 and below are
sealed off from the crankcase lubricant by oil seals and run in a separate bath
of oil retained in the respective bearing housing.
WARNING -
The
crankcase is drained after testing pump at the factory. Remove crankcase cover
or crosshead guide hand hole cover and fill with sufficient lubricant before starting
the pump for the first time.
CRANRCASE OIL -
Quantity and
type of lubricant required to fill crankcase to proper level is shown below.
For
herringbone gear driven pumps operating in average climates, use SAE 90EP, AGMA
5EP, or AGMA 6EP gear lubricants. Be sure, however, to use an EP lubricant that
will not have a corrosive action on Bronze and that it contains rust, oxidation
and foam inhibitors. multi-purpose multi-viscosity gear lubricants are UNSATISFACTORY
for use in Gaso pumps.
For chain and sprocket driven pumps use an SAE 30 high
grade mineral oil in Crankcase.
For worm driven pumps, use an SAE 140
EP Gear Lubricant.
Running temperature of crankcase oil should not
exceed 180 degrees Fahrenheit. If higher temperatures occur and mechanical fits
are found to be correct the use of a separate oil cooler is recommended. In addition,
SAE EP 140 Gear Lubricant should be placed in separate bath bearings on pump where
they are standard.
For low ambient temperatures, select an oil with
a pour point lower than the lowest anticipated ambient temperature. Consult Gaso
factory for recommendations when unusual operating conditions exist.
GASO
DUPLEX PISTON POWER PUMPS POWER END (Continued)
PUMP CRANKCASE CAPACITY
-
PUMP
SERIES 1800 2200 1500 1550-C 2000 1600 1654-C 1700
1900 2600
U.S. GALLON 5 5 10 6 10 12 8 15 21 25
As soon as
above lubricant has been added, replace crankcase cover and install breather(s)
on top to provide for ventilation.
DAILY INSPECTION OF OIL IN CRANKCASE
-
Check oil level and appearance daily. Change oil and clean breather
every six months or 2000 hours running time, more often under severe operating
conditions. The crankcase should be thorouqhly cleaned at each oil change. Contamination
of the oil by saltwater will be indicated in only a few hours by the oil turning
white, milky, or foamy. Contamination of the oil by moisture condensation will
be indicated by the oil slowly turning dark or a rusty brown.
Whenever any
type of contamination or dilution is detected, drain the crankcase, remove the
crankcase cover and crosshead guide handhole cover, thoroughly flush out the oil
and refill with clean oil as necessary to bring to full mark on the dipstick.
Do not overfill. At the same time, check and clean breather. oil lost by leakage
should be replaced before the level becomes too low. If loss is excessive, check
the packing in the crankcase stuffing boxes, the oil retainer on the pinion shaft,
and clean the crankcase breather.
LUBRICATION OF SHAFT BEARINGS IN SERIES
1550-C, 16540C, 2000 and 2200 - (AND FOR PUMPS #24523 AND BELOW) These pumps are
equipped with inner oil seals on pinion shaft and crankshaft, so they run in a
separate bath of SAE EP 90 Gear Lubricant or SAE 50 high grade motor oil or mineral
oil. The correct amount of oil is put into the bearing housings when pump is shipped
from factory, but a check should be made to see that none has leaked out or been
removed. Proper oil level is even with pipe plug in lower part of bearing housing
flange or cover plate.
Inspection should be made regularly to determine
if any loss has occurred by leakage past the oil seals. If necessary add oil through
plugged hole in top of bearing housing flange. Do not fill above "oil level"
as too much oil will churn and create excessive heat. Remove cover plates, flush
with kerosene, inspect bearings, and refill with clean oil at least once every
six months.
Normal running temperature is 140° to 160°F.
GASO
DUPLEX PISTON POWER PUMPS POWER END
Pumps with herringbone gears #24523
and up do not have inner oil seals installed for the pinion and crankshaft bearings
as standard equipment however, you pump may have these seals installed as special
equipment. if your pump has inner oil seals installed, the amount of oil required
for the crankcase is as follows:
PUMP
SERIES 1800 2200 1500 2000 1600 1700
1800 2600
U.S.GALLON 2-1/2 5 6 10 8 10 15 18
CONNECTING ROD
BEARINGS, CRANK END -
Inspect connecting rod bearings and adjust as
necessary every six months or when crankcase lubricant is changed. The bearings
in the crank end are babbitt lined steel shells, adjustable for wear by
removing
shims and easily replaced when completely worn. These bearings should be watched
closely and adjusted to compensate for wear. You will note that shims do not completely
fill the outer gap between rod and cap casting although the connecting rod bolts
are tight. This is because the faces of the shell bearings project slightly beyond
the faces of the rod and cap castings and the shims are gripped only between the
faces of the bearing halves. Do not try to close this outer gap by tightening
the connecting rod bolt as it will put an excessive strain on them.
To
check for wear, place a wrench on the top connecting rod bolt and shake the rod
parallel to the crankshaft. (The pressure must be relieved from the liquid end
of the pump so that the pump's mechanism is free to move.)
If the rod bearing
moves without resistance, the bearing may be too loose and need adjusting. If
the bearing does need adjusting, remove shims until you cannot shake the rod,
then add .005" shims one at a time until there is a little side movement.
Be sure to torque rod bolt nuts to proper value for each adjustment. (NOTE: If
you are making this adjustment after having had the crossheads out, be sure that
the oil holes in the rod are pointing up. The "up" side is indicated
by matching numbers stamped on the cap and rod at the split between them. These
numbers should be the same on each rod and should be on the top side of the crankshaft.)
Turn the shaft by hand and if there is any hard drag or tight spots in the bearing,
add another .005" shim. After this bearing is properly adjusted, loosen bolts
a few turns and repeat the above operation on the other bearings. After all bearings
have been adjusted, torque all connecting rod bolt nuts back to proper amount.
Again turn the pump by hand to check for excessive drag and tight spots. If none,
the pump should then be ready for operation.
If the pump cannot be rotated
by hand due to the drive being enclosed, the bearings may be completely adjusted
by shaking the bearing on the shaft as stated above. Care must be taken not to
over-tighten the bearings since they cannot be checked by rotating the pump by
hand. When bearings are adjusted by this method, they must be watched carefully
for overheating when the pump is put into operation.
Alternatively, plastic
gauge strips, found in most parts stores may be used to adjust these bearings.
It is usually better to have a bearing a little too loose than too tight.
A slightly loose bearing will cause very little trouble because of the slow operating
speeds of the pump, but a tight bearing will overheat and the babbitt may melt
or pull. with experience, an operator can tell by feel when the bearings are properly
adjusted. Normal precautions must be taken to insure cleanliness of parts upon
their assembly. All wrenches used in adjusting these bearings are standard wrenches.
CLEARANCE
ON CONNECTING ROD BEARINGS, CRANK END:
Pump Fig. No. Dia. of Crank
Pin Clearance
1800 3.000" .002"
1500 3.750" .002"
- .003"
1600 4.250" .002" - .003"
1700 4.750"
.002" - .003"
2600 6.500" .008"
RECOMMENDED
TORQUE WRENCH SETTINGS FOR CONNECTING ROD BOLT NUTS
Torque 2500 In. -Lbs.
4500 In.-Lbs. 6000 In.-Lbs.
PUMP FIGURE# 1845 1507 1742
1849 1550 1755
1847 1563
1743
2245 2017 1753
2249 2050 2651
2247 2063 2652
1654 1931
In.-Lbs.
CONNECTING ROD BEARINGS, CROSSHEAD END -
Bearings
in the crosshead end are bronze bushings. To replace these bushings, remove connecting
rod and crosshead assembly from pump. Press out the crosshead pin, and then remove
and replace bushing. After the new bushing has been pressed into the connecting
rod, it should be reamed for a loose fit on the crosshead pin as follows: .002"
for pumps Series 1500, 1800, and 1700, .0025" for pumps Series 1600, and
.004" for pumps Series 2600.
GASO DUPLEX PISTON POWER PUMPS POWER
END (Continued)
Before replacing crosshead pin, always inspect pin and crosshead
for burrs. Then press-in pin, using an anti-seize compound as lubricant.
CRANKSHAFT
BEARINGS -
Crankshaft bearings are single tapered roller bearings and
are splash-lubricated from oil in the crankcase. These should be flushed clean
and carefully inspected and adjusted as necessary at least once every six months,
or whenever crankcase lubricant is changed.
Crankcase bearings for Series
1800, 1500, 1600, and 1700 pumps should have an end play in the crankshaft of:
.001" to .003" for 1800 pumps
.002" to .004"
for 1500 pumps & 1600 pumps .003" to .005" for 1700 pumps
This
end play is measured when pump is cold to allow for expansion due to heat under
operating conditions.
Bearings may be adjusted from one side only.
To adjust bearings for end play, disconnect connecting rods, remove several shims
(more than necessary) from under the bearing housing, tighten up on crankshaft
bearing housings until bearings bind slightly when shaft is rotated by hand. Then
measure the shim gap with a feeler gauge and add its equivalent plus from .001"
to .003" of shim (for normal clearance) and tighten up on crankshaft bearing
housing cap screws.
Crankshaft bearings for series 2600 Pumps have a .012"
to .013" pre-load. To get this pre-load, try different thicknesses of shims
until a slight drag is felt while rolling the shaft and then remove .012"
to .013" of shims.
When necessary to install new bearing cones on crankshaft,
heat them in oil at 280 degrees Fahrenheit for easy installation. Be sure they
are firmly against the shoulder on the crankshaft.
Please note: Improper application
of heat to these bearings during their installation in Gaso pumps will automatically
revoke the warranty on the bearings. It is suggested that the procedures outlines
above be closely followed when changing bearings.
PINION SHAFT BEARINGS
-
The pinion shaft bearings are self-contained ball or roller bearings
and have no adjustment for wear. Their load ratings are far above the load applied
and will therefore have very little wear if properly lubricated.
GEARS
There are two principal
types of Gaso Piston Pumps which use gears; those with herringbone gear reduction
and those with worm gear reduction.
The herringbone gears are continuous tooth
Sykes design. Pinion
gear is alloy steel and keyed to the pinion shaft. Main
gear is a high grade semi-steel or ductile iron casting, with internal flange
for bolting to crankshaft with cap screws. Gear teeth may show signs of slight
pitting after being run awhile, but with proper lubrication this will cease and
teeth will smooth up.
Meshing of these herringbone gears provides the
principal method of lubricating the pinion and crankshaft bearings. Therefore,
the pinion must be turning in the direction specified on the power frame casting
and the gears must be meshing so the center part of the gear teeth come together
first.
Although pumps may run backwards without adversely affecting
operation, always run them faster than 75 strokes per minute or install inner
oil seals for pinion shaft and crankshaft bearings.
In worm-driven pumps, the
main or ring gear, is of special nickel alloy bronze with internal flange for
bolting to center disc of crankshaft. The driving worm and shaft is one piece,
of chrome nickel steel, hardened and ground. This worm and shaft is removable
through the end of worm case toward the liquid end of pump but it will first be
necessary to remove the flexible coupling, stuffing box, and thrust bearing jam
nut from other end of shaft. The thrust bearings will slide off when shaft is
withdrawn.
To remove crankshaft and main gear, take out cap screws holding
oil reservoir half-ring to inner end of main bearing housing, remove bearing housing
clamps and pull main bearing housings outward until free of bearings. Then lift
crankshaft and gear assembly out. Support crankshaft and gear assembly with a
block or hoist before pulling the bearing housings outward.
SPROCKETS -
Series
1550-C and 1654-C pumps use quadruple row internal sprockets with specially made
heavy duty quadruple row chain. The driving pinion shaft and sprocket is one piece
with Nitride Hardened sprocket teeth.
The main sprocket is of alloy steel,
with internal flange for bolting to center disc of crankshaft. To remove crankshaft
and main sprocket, pull master link from chain, remove cap screws holding oil
seal rings to inner end of main bearing housing, remove bearing housing clamps
and pull main bearing housings outward until free of bearings. Then lift crankshaft
and gear assembly out. Support crankshaft and sprocket assembly with a block or
hoist before pulling the bearing housing outward.
PISTON ROD STUFFING
BOXES AND PACKING -
The piston rod stuffing boxes in power end of pump
are packed at the factory. The purpose of this packing is to wipe the piston rod
clean and thus prevent contamination of lubricant in the crankcase and also to
prevent loss of oil from the crankcase. Adjust this packing by evenly tightening
the packing gland cap screws until leakage is minimized.
GASO DUPLEX
PISTON POWER PUMPS LIQUID END
Over a period of time, beginning may,
1978, all liquid end bodies for Duplex Piston Pumps were gradually redesigned
to accept an O-ring mounted in a bevel at the opening of the valve covers, cylinder
heads and stuffing boxes. This re-design allowed the flange of the valve cover,
cylinder head, or stuffing box to fit metal-to-metal with the liquid body. Prior
to this re-design most of these liquid ends were counter-bored to accept a flat
gasket which caused a gap between the flanges of the valve covers, cylinder head,
or stuffing boxes and the liquid end. BEFORE YOU REPAIR YOUR PUMP, MAKE A VISUAL
CHECK TO SEE
WHAT TYPE OF VALVE COVER, CYLINDER HEAD, AND STUFFING BOXES ARE
ON THE PUMP.
The list of serial numbers below will serve as a general
guide to the first pumps fitted with o-rings, but does not guarantee that your
pump has them. You must check your pump before ordering parts for it. The first
number is the pump serial number, the second number is the liquid end serial number:
1st
Fig 1847-A # 41451 - 2053
1st
Fig 1550 # 40162 - No liquid end number
1st
Fig 1550-C # 40137 - No liquid end number
1st
Fig 1654 # 40164 - No liquid end number
1st
Fig 1654-C # 40007 - No liquid end number
1st
Fig 1742 # 41785 - 2410
1st
Fig 1755 # 41778 - 2406
1st
Fig 1753 # 42376 - 2994
1st
Fig 2651 # 42224 - 2851
1st
Fig 2652
# 42029 - 2668
1st
Fig 1757 and 1759 liquid bodies are beveled for O-rings.
PISTON
ROD STUFFING BOXES AND PACKING -
Liquid end stuffing boxes on a new
pump must be packaged by the user before the pump is put into service. The necessary
packing will be found in small sacks packed in a box with other pump accessories.
Standard packing consists of lip type packing rings. These function best when
not squeezed up too tight. Special packing sometimes furnished consists of square
graphited duck and rubber packing rings. These require more pressure to seal off
fluid satisfactorily, but care should be exercised to avoid over-tightening. Good
practice is to let packing leak slightly.
PISTONS
Standard
pistons for crude oil service consist of cast iron or steel bodies with special
patented cast iron porous chrome faced piston rings. Cast iron or steel piston
bodies with nylon glass filled piston rings are furnished pumping crude oil products.
Cup type pistons are furnished for pumping saltwater and rubber inserted pistons
are used for slush and cementing service.
To replace pistons, remove crosshead
jam nuts and power end and liquid end stuffing box glands and packing. Remove
cylinder heads and pull rod, piston and liner through front of liquid end. Install
new
pistons, rings or cups is required. Insert pistons on to rod and into liners,
oriented with front of piston toward flange end of liner. Install new liner gasket,
and slip liner, piston and rod assembly into pump. Be sure to slip packing glands
over rod before pushing rod thru power end stuffing box. Run crosshead jam nut
onto rod as far as possible, positioned so flat face of nut will bear upon face
of crosshead. Run rod into crosshead until jam nut touches crosshead, then tighten
jam nut against crosshead. Be sure all mating surfaces are dry and clean before
tightening nuts against pistons or crossheads. Note: torque all nuts holding pistons
to rod to 7.200 in.-lbs.
Holding liner in place, roll pump one complete revolution
to verify that piston is centered in the liner (end of cast iron piston may stroke
out of liner), and adjust as necessary by repositioning the crosshead jam nut
on the rod. Once centered, install the packing, glands, and cylinder heads. (See
instructions for tightening liner set screws below.)
Slush type pistons generally
require more frequent attention than other types of pistons.
LINERS
-
standard liners for crude oil service are cast iron. Liners for saltwater
service are corrosion resistant material. Hardened steel liners are recommended
for slush pump service. Always use new gaskets when changing liners.
LINER
SET SCREWS -
There are four Liner Set Screws with jam nuts in each
cylinder head. These are to hold the liner against the liner gasket. When installing
cylinder head, back the liner set screws out a little and
then tighten all
nuts on cylinder head studs first. Be sure to work around the cylinder head from
nut to nut until all are tightened evenly. Then tighten set screws against the
liner, torque to 2880 in.-lbs. with the exception of Fig. 1849 pumps which are
torqued to 2400 in.-lbs. again working evenly. Lastly, tighten the jam nuts on
these set screws. Be sure that packing or lead gasket is in the cupped space on
underside of jam nut.
VALVES AND VALVE SEATS -
Standard equipment
for crude oil service consists of hardened and ground steel wing guided valves
and seats.
1st Fig
Bronze wing guided valves
and seats are usually furnished for fresh or saltwater service. Tops of valve
stems are slotted so that valve can be rotated in the pump to regrind valve and
seat faces with grinding compound. When worn too badly, they can be removed and
faced off in a lathe.
Insert type valve assemblies consist of a bronze, steel,
or cast iron winged body, a Bakelite disc insert, and a metal cap plate all held
together with a cap screw. Inserts made from plastic can also be furnished. Inserts
will require occasional renewal. Top of seat surface which contacts insert should
be inspected at reasonable intervals and reground if marred.
Slush pump
valves require frequent replacement of rubber inserts due to the very abrasive
material being pumped. Valves and seats should be inspected before starting and
when finishing any drilling job.
When replacing valve seats, clean valve seat
and mating taper in liquid end with a cleaner that does not leave an oil film
or residue. Wipe with a clean, dry rag. CAUTION: SEAT AND TAPER IN LIQUID END
MUST BE ABSOLUTELY CLEAN AN DRY BEFORE DRIVING SEAT INTO PUMP TAPER.
CYLINDER
HEADS AND VALVE COVERS AND STUFFING BOXES -
Valve covers and Cylinder Heads
are held to the liquid body with studs and nuts. These nuts should be torqued
to the following values according to size.
3/4" - 2,880 in-lbs
7/8"
- 4,800 in.-lbs.
1" - 7,200 in.-lbs
Note: If the pump is EVER
overloaded (loaded above maximum recommended published pressures) or if a stud
EVER fails for any reason whatsoever, REPLACE ALL STUDS IN THE LIQUID BODY BEFORE
USING THE PUMP AGAIN.
GASKETS -
Pumps are equipped with O-Ring gaskets
for valve covers, cylinder heads, and stuffing boxes, and with flat fiber gaskets
for suction and discharge flanges. Separate lantern rings and "tattle-tale"
packing is furnished as gaskets for liners in recently manufactured slush fitted
pumps, while pumps fitted for other applications are equipped with spacers and
flat fiber liner gaskets. Always be sure that all gasket surfaces are smooth and
dry and free of any particles which would scratch or otherwise interfere with
efficient operation of the gasket.
GASO DUPLEX PISTON POWER PUMPS LIQUID
END
RECOMMENDED WORKING PRESSURES AND CAPACITIES -
Piston
displacement and recommended working pressure for continuous duty and with various
size liners are shown in the current Gaso catalog.
When pumping relatively
incompressible liquids, volumetric efficiency of pump when valves and liners and
pistons are in good shape should be from 95% to 96%. If actual output of pump
does not equal 95% of displacement figures shown at the respective speeds, cause
o£ trouble may be foreign matter lodged under valve, bad valve facing, worn
liners, worn piston rings, or blown liner gasket. Too small a suction line may
also be cause of shortage.
SUCTION LINES -- (REFER TO DIAGRAM)
Flush suction
lines thoroughly before starting pump.
Always provide ample capacity
suction lines to the pump. This is the first requisite when installing a GASO
pump. The pump cannot function properly if an inadequate quantity of fluid is
furnished it. For suction lines leading directly to the pump, select a size line
so that the velocity of the fluid will not exceed 12 feet per second, or one that
is two sizes larger than the pump suction connection, whichever gives the slower
line velocity. The last to to 15 feet of this line is preferably flexible hose
and should always be connected to the pump inlet with an eccentric reducer (with
straight portion on top).
Always size "headers" feeding more
than one pump so that the maximum velocity in the header with all pumps running
will not exceed 1 foot per second.
NEVER USE PLUG-TYPE VALVES IN A SUCTION
LINE. USE FULL OPENING VALVES. Keep the number of turns to a minimum. When turns
are required, use long radius ells.
In pumping gaso lines or light volatile
liquids such as butane and propane, design your system so that the positive suction
head at the pump is at least 35 pounds per square inch (psi) above the vapor pressure
of the fluid. When pumping water or average crude oils, 10 to 15 psi gauge pressure
at the pump will usually be sufficient if pump speed does not exceed 54 RPM. If
pump is running at higher speeds, provide for a minimum additional pressure of
15 psi at the pump inlet.
Always connect to two sides of pumps with multiple
suction inlets. This will help insure proper filling of the pump. If unable to
connect to two sides, use a properly sized suction stabilizer, mounted and charged
according to instructions with stabilizer.
Contact IEQ Industries at 800.544.9053
for further assistance in design of your supply tank and piping system.
Contact IEQ Industries at 800-544-9053 for further assistance in design of your supply tank and piping system.
GASO.com is a reseller of new used and remanufactured Wheatley, GASO and Wheatley/GASO pumps and is not affiliated with Wheatley/GASO Inc. or it's parent company