Gardner Denver FXF - 5" Service manual

GARDNER DENVER
DUPLEX POWER PUMP
MODELS:
FXF – 5”
FXG – 6”
FXX – 8”
FXD – 10”
FXE – 10”
OPERATING AND
SERVICE MANUAL
3–600
6th Edition
June, 1997

3–600 Page i
MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
GENUINE GARDNER DENVER
PARTS AND SUPPORT SERVICES
Gardner Denverand OPIgenuine pump parts are
manufactured to original tolerances and designed for
optimum dependability. Design and material innova-
tions are the result of years of experience with
hundreds of different pump applications. Reliability in
materialsandqualityassuranceareincorporatedinour
genuine replacement parts.
Your authorized Gardner Denver and OPI distribu-
tor offers all the backup you’ll need. A worldwide
network of authorized distributors provides the finest
product support in the pump industry.
Your local authorized distributor maintains a large in-
ventory of genuine parts and he is backed up for emer-
gency parts by direct access to the Gardner Denver
Machinery Inc. Master Distribution Center (MDC) in
Memphis, Tennessee.
Your authorized distributor can support your Gardner
Denver and OPI pump needs with these services:
1. Trained parts specialists to assist you in select-
ing the correct replacement parts.
2. Repair and maintenance kits designed with the
necessaryparts tosimplify servicingyour pump.
Authorized distributor 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 and OPI distributor refer to the yellow pages
of your phone directory or contact:
Distribution Center: Factory:
Gardner Denver Machinery Inc. Gardner Denver Machinery Inc.
Master Distribution Center 1800 Gardner Expressway
5585 East Shelby Drive Quincy, IL 62301
Memphis, TN 38141 Phone: [phone]
Phone: [phone] Fax: [phone]
Fax: [phone]
INSTRUCTIONS FOR ORDERING REPAIR PARTS
When ordering parts, specify Pump MODEL and SE-
RIAL 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 near-
est authorized distributor.
Where NOT specified, quantity of parts required per
pumporunitisone(1);wheremorethanoneisrequired
perunit,quantity isindicatedin parenthesis. SPECIFY
EXACTLY THE NUMBER OF PARTS REQUIRED.
DO NOT ORDER BY SETS OR GROUPS.
To determine the Right Hand and Left Hand side of a
pump,standatthe power end and looktowardthefluid
end. Right Hand and Left Hand are indicated in paren-
thesis following the part name, i.e. (RH) & (LH), when
appropriate.

3–600 Page ii
FOREWORD
GardnerDenverandOPIpumpsaretheresultofadvancedengineeringandskilledmanufacturing.Tobeassured
of receiving maximum service from this machine the owner must exercise care in its operation and maintenance.
This book is written to give the operator and maintenance department essential information for day–to–day opera-
tion, maintenance and adjustment. Careful adherence to these instructions will result in economical operation and
minimum downtime.
Danger is used toindicate the presenceof a hazardwhich willcause severe personal
injury, death, or substantial property damage if the warning is ignored.
Warning isusedto indicatethepresence ofahazard which cancausesevere person-
al injury, death, or substantial property damage if the warning is ignored.
Caution is used to indicate the presence of a hazard which will or can cause minor
personal injury or property damage if the warning is ignored.
Notice is used tonotify peopleof installation, operationor maintenanceinformation
which is important but not hazard–related.

3–600 Page iii
TABLE OF CONTENTS
Introduction i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts Ordering Instructions i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger Notices, Section 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Operating Instructions, Section 2 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance & Service Instructions, Section 3 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions & Running Clearances, Section 4 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TroubleShooting, Section 5 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations
Figure 1 Crankcase Oil Requirements 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2 Lubrication Fill Rate 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3 Packing Type Piston 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4 Cup Type Piston 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5 Piston Textures 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6 Piston Rod 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7 Rotation of Eccentric 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8 Jackshaft Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9 Eccentric and Main Shaft Assembly 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10 Crosshead Pin Removal – FXX, FXD & FXE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3–600 Page iv
INDEX
Baffle, Fluid Piston Rod 9. . . . . . . . . . . . . . . . . . . . . . . .
Boiler Feed or Low Pressure Water Service 8. . . . . . .
Clean Oil or Petroleum Products Services 9. . . . . . . .
Covers and Guards, Danger Notice 2. . . . . . . . . . . . . .
Crosshead Pin Removal – FXF & FXG Pumps 12. . .
Crosshead Pin Removal – FXX, FXD & FXG 13. . . . .
Daily Care 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DANGER NOTICES, SECTION 1 1. . . . . . . . . . . . . . .
Danger Notices
Covers and Guards 2. . . . . . . . . . . . . . . . . . . . . . . .
Equipment Moving and Lifting 2. . . . . . . . . . . . . . .
Flammable, Hot, Cold or Corrosive Fluid
Pumping 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hammer Lug Fasteners 1. . . . . . . . . . . . . . . . . . . .
High Pressure Liquid Jetting, Blasting and
Cleaning 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressurized Pump Systems 3. . . . . . . . . . . . . . . . .
Valve Seat Pulling 2. . . . . . . . . . . . . . . . . . . . . . . . .
Wedge Puller 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data for FXD, FXE and FXX Power Pumps 16. . . . . .
Data for FXG and FXF Power Pumps 17. . . . . . . . . . .
Dimensions
Fluid End Piston Rod Stuffing Box 15. . . . . . . . . .
Power End Oil Stop Head 15. . . . . . . . . . . . . . . . . .
DIMENSIONS & RUNNING CLEARANCES,
SECTION 4 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Moving and Lifting, Danger Notice 2. . . . .
Flammable, Hot, Cold or Corrosive Fluid Pumping,
Danger Notice 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Cylinder Liner Packing 9. . . . . . . . . . . . . . . . . . . .
Fluid Cylinder Liners 10. . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Discharge Piping 7. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid End Parts 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid End Piston Rod Stuffing Box Dimensions 15. . .
Fluid Inlet or Suction Piping 7. . . . . . . . . . . . . . . . . . . . .
Fluid Piston Rod Baffle 9. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Piston Rod Packing 9. . . . . . . . . . . . . . . . . . . . . . .
Fluid Pistons and Packing 8. . . . . . . . . . . . . . . . . . . . . .
Fluid Valves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Oil Stop Head Packing 9. . . . . . . . . . . . . . . . . . .
FXE Main Gear and Eccentric 13. . . . . . . . . . . . . . . . . .
Hammer Lug Fasteners, Danger Notice 1. . . . . . . . . .
High Pressure Liquid Jetting, Blasting and Cleaning,
Danger Notice 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Pistons for Abrasive Service 9. . . . . . .
High Pressure Special Fluid Service 8. . . . . . . . . . . . .
High Temperature Service 9. . . . . . . . . . . . . . . . . . . . . .
Hydraulic Puller, Danger Notice 2. . . . . . . . . . . . . . . . .
Inspection, Occasional 12. . . . . . . . . . . . . . . . . . . . . . . .
Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION AND OPERATING INSTRUC-
TIONS, SECTION 2 7. . . . . . . . . . . . . . . . . . . . . . . .
Installation of Jackshaft Oil Seals 12. . . . . . . . . . . . . . .
Jackshaft, Removal 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting and Moving Equipment, Danger Notice 2. . . . .
Liners, Fluid Cylinder 10. . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Water or Boiler Feed Service 8. . . . . . .
Lubrication 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearings, Install 13. . . . . . . . . . . . . . . . . . . . . . . . .
Moving and Lifting Equipment, Danger Notice 2. . . . .
Occasional Inspection 12. . . . . . . . . . . . . . . . . . . . . . . .
Operating Speeds and Pressures 14. . . . . . . . . . . . . .
Ordering Instructions, Repair Parts i. . . . . . . . . . . . . .
Packing
Fluid Cylinder Liner 9. . . . . . . . . . . . . . . . . . . . . . . .
Fluid Piston Rod 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Oil Stop Head 9. . . . . . . . . . . . . . . . . . . . . . .
Packing and Fluid Pistons 8. . . . . . . . . . . . . . . . . . . . . .
Piping 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Discharge 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Inlet or Suction 7. . . . . . . . . . . . . . . . . . . . . . .
Suction or Fluid Inlet 7. . . . . . . . . . . . . . . . . . . . . . .
Piston, Fluid 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rods 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power End Oil Stop Head Dimensions 15. . . . . . . . . .
Pressures and Operating Speeds 14. . . . . . . . . . . . . .
Pressurized Pump Systems, Danger Notice 3. . . . . .

3–600 Page v
Recommended Running Clearances
FXD, FXE and FXX Power Pumps 16. . . . . . . . . .
FXG and FXF Power Pumps 17. . . . . . . . . . . . . . .
Relief Valve 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts, Ordering Instructions i. . . . . . . . . . . . . .
Repair Parts Maintenance 13. . . . . . . . . . . . . . . . . . . . .
Repair Parts Ordering 13. . . . . . . . . . . . . . . . . . . . . . . . .
Rods, Piston 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROUTINE MAINTENANCE & SERVICE
INSTRUCTIONS, SECTION 3 12. . . . . . . . . . . . . .
Service
Abrasive, High Pressure Pistons 9. . . . . . . . . . . . .
Boiler Feed 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Oil or Petroleum Products 9. . . . . . . . . . . . .
High Pressure Special Fluid 8. . . . . . . . . . . . . . . . .
High Temperature 9. . . . . . . . . . . . . . . . . . . . . . . . .
Low Pressure Water 8. . . . . . . . . . . . . . . . . . . . . . .
Specifications, Torque 18. . . . . . . . . . . . . . . . . . . . . . . .
Starting a New Pump 10. . . . . . . . . . . . . . . . . . . . . . . . .
Storage of Pump, Special Care 14. . . . . . . . . . . . . . . .
Suction or Fluid Inlet Piping 7. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 18. . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING, SECTION 5 19. . . . . . . . . . . .
Valve, Relief 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Pulling, Danger Notice 2. . . . . . . . . . . . . . .
Valves, Fluid 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Last Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wedge Puller, Danger Notice 2. . . . . . . . . . . . . . . . . . .

3–600 Page 1
SECTION 1
DANGER NOTICES
Read and understand the following DANGER NO-
TICES before moving or operating the pump or any
pump package unit equipment.
Reciprocatingpumpsaremachinescapableofproduc-
ing high fluid pressures and flow rates and are de-
signed to be used with proper care and caution by
trained, experienced operators. TO AVOID PER-
SONAL INJURY, DEATH AND/OR EQUIPMENT
DAMAGE, READ AND THOROUGHLY UNDER-
STAND THE FOLLOWING DANGER NOTICES
PLUS THE ENTIRE OPERATING AND SERVICE
MANUAL BEFORE ATTEMPTING TO MOVE OR
OPERATE THE PUMP. Contact a Gardner Denver
Machinery service representative if you are unable to
comply with any of the danger notices or procedures
described in these documents.
Closely examine the data plate upon pump delivery to
becomethoroughlyfamiliar with theoperatinglimits for
thispumpmodel. The pumpmustneverbe operated
at speeds, pressures or horsepower exceeding the
maximum values shown on the data plate or at
speeds below the minimum shown. Failure to ob-
serve the operating limits shown on the data plate
could result in personal injury, death, and/or
equipment damage and will void the warranty. Al-
terations to the pump, or application of the pump out-
side the data plate limits, must not be made without
Gardner Denver Machinery written approval together
with a new data plate, as dangerous operating condi-
tions could result.
THE DANGER NOTICE AND DATA PLATES PRO-
VIDED ON THE EQUIPMENT MUST NOT BE RE-
MOVED, PAINTED OVER, HIDDEN OR DEFACED.
Theymustbereplaced if theybecomedamagedor un-
readable. Provisions should be made to have the fol-
lowing written danger notices plus the pump operating
and service manual readily available to operators and
maintenancepersonnel. Inaddition,copiesofallpump
system accessory component (e.g. pressure relief
valve, pulsation dampener, suction stabilizer, engine,
electric motor, etc.) operating and service manuals
should be readily available for operator and mainte-
nance personnel use. Read and follow all the precau-
tions and instructions contained in these manuals. If
any of these documents are lost or become illegible
they must be replaced immediately. The danger no-
ticesplus theoperatingandservicemanualsshouldbe
rereadperiodicallybybothoperatorsandmaintenance
personneltorefreshtheirmemoriesinsafeprocedures
and practices.
Keep in mind that full operator attention and alertness
are required when operating high pressure pumping
equipment. Operatorsshouldnotbeginorcontinueop-
erationswhentired,distractedorundertheinfluenceof
alcohol or any type of prescription or nonprescription
drugs.
The timely replacement of expendable parts and any
other worn or damaged parts can prevent equipment
damage and possible injury. The original parts used in
GardnerDenverpumps are designedandtested to ex-
acting standards to provide high quality performance
and durability. Your best insurance in maintaining
thesecharacteristicsistousegenuineGardnerDenver
replacement parts.
A broad range of danger notices are covered on these
pages,however, theycannot substitutefortraining,ex-
perience and common sense in the safe operation of
high pressure pumping equipment.
HAMMER LUG FASTENERS
On pumps or pump package units equipped with ham-
mer lug connectors and/or hammer lug valve covers
the following precautions must be observed to avoid
personal injury, death and/or equipment damage due
to contact with the hammer, hammer bar, broken parts
from the hammer, hammer bar or lugs or other objects
propelled by hammer blows. When tightening or loos-
eninghammerlugconnectorsandvalvecovers,opera-
tors or maintenance personnel should:
SInspectthehammer,hammerlugsandhammer
bar, if one is used, to insure they are all in good
condition. Replaceanyofthesepartswhichare
cracked, damaged or badly worn.
SWear safety shoes and goggles.
SAlert other personnel to move away from the
area.
SCheck to insure they have safe footing.
SFully engage the hammer bar, if one is used, to
prevent it from disengaging violently from the
cover as a blow is struck.
SWipe their hands and the hammer handle and
maintainafirmgriponthehandletoavoidlosing
control of the hammer while swinging and strik-
ing.

3–600 Page 2
SCarefully swing the hammer to avoid striking
themselves, another person and objects other
than the targeted lugs or hammer bar.
SAvoid swinging the hammer above shoulder
height.
VALVE SEAT PULLING
The following precautions must be observed by opera-
torsandmaintenancepersonneltoavoidpersonalinju-
ry, death and/or equipment damage from contact with
the puller, hammer, wedge or broken parts from these
components when using either a hydraulic or wedge
valve seat puller:
Hydraulic Puller
SWear safety shoes and goggles.
SChainortiethejackdownasitwilljumpviolently
when the valve seat disengages from the valve
deck.
SChecktoinsurethepressureapplied by the hy-
draulic pump does not exceed the hydraulic
ram maximum pressure rating.
Wedge Puller
SGrind off any mushroomed material from the
wedge before use.
SFollow the danger notices listed above in the
hammer lug section, but substitute the term
wedge for hammer lug and hammer bar.
COVERS AND GUARDS
All pump covers must be securely
fastened in proper position at all
times when the pump is operating to
avoid personal injury or death from
moving parts. In addition, all moving
parts on the entire pump package, in-
cluding but not limited to engine or
motors, drive shafts, belts, chains,
pulleys, gears, etc.,must beequipped
with guards or covers, which must
also be securely fastened in proper
position at all times when the equip-
ment is operating.
Covers and guards are intended to not only protect
against personal injury or death, but to also protect the
equipment from damage from foreign objects.
EQUIPMENT MOVING AND LIFTING
Heavy equipment including pumps, pump package
units and components should only be moved or lifted
by trained, experienced operators, who are physically
andmentallypreparedtodevotefullattentionandalert-
ness to the moving and lifting operations. An operator
should be fully aware of the use, capabilities, and
condition of both the equipment being moved and the
equipment being used to move it.
Failure to follow safe and proper
pump, pump package or component
lifting or moving procedures can lead
to personal injury, death and/or
equipment damage from shifting, fal-
ling or other unexpected or uncon-
trolled equipment movements.
Make sure the hoist, lift truck, ropes, slings, spreader,
orotherliftingequipmentyouareusingisingoodcondi-
tion and has a rated lifting capacity equal to or greater
than the weight being lifted. Lifting devices must be
checkedfrequentlyforconditionand continued confor-
mance to rated load capacity. They should then be
tagged with the inspected capacity together with the
date of inspection.
Fully assembled pumps and pump package units are
heavy and should only be moved using the specified
lifting lugs or attachments. Many individual compo-
nents have lifting eyes or lugs which must not be
used to lift assemblies, as they are designed to
bear the weight of the component only. Before lift-
ing the individual component check to insure the lifting
attachmentisfirmly secured to thecomponentwith un-
damaged, properly torqued fasteners, sound welds, or
other secure attachments. Examine the lifting eyes,
lugs, slots, holes or other projections to insure they are
not cracked, otherwise damaged or badly worn. The
repair of existing or addition of new welded lifting eyes,
lugs or other projections should only be performed by
experienced, qualified welders.
Package units should be lifted with spreaders con-
nected to the lifting attachments normally built into the
packageunitsupportskid. Packagestoolargetoliftful-
ly assembled should be separated into smaller loads.

3–600 Page 3
For these smaller loads the lifting devices should be
fastened to the lifting attachments normally built into
the individual motor, engine, pump or transmission/
torque converter, or their separate support skids.
When lifting subassembled components, for example
a suction stabilizer attached to suction piping or a dis-
chargepulsationdampenerattachedtoastrainercross
and piping, use special lifting slings designed to safely
support the combined weight of the components.
Ifacrane orhoist isbeingused toliftlarge components
or assemblies, one or more persons should assist the
operator from the ground with guide lines attached to
the equipment being moved to properly position it and
prevent uncontrolled movement.
Whenyou starttoliftapump, packageunit, subassem-
blies or individual components and you observe the
equipment is tilting, or appears unbalanced, lower the
equipment and adjust the lifting device to eliminate
these improper lifting conditions before proceeding to
move the equipment.
It is poor practice and dangerous to allow the equip-
ment to pass over or close to your body or limbs. Be
prepared to move quickly out of danger if equipment
starts to fall, slip or move unexpectedly toward you.
PRESSURIZED PUMP SYSTEMS
Fluids under high pressure can pos-
sess sufficient energy to cause per-
sonal injury, death and/or equipment
damage either through direct contact
withescapingfluidstreams orbycon-
tact with loose objects the pressur-
ized fluid propels.
Operating a pump against a blocked or restricted dis-
chargelinecanproduceexcessivepressuresintheen-
tire discharge system, which can damage or burst dis-
charge system components.
Never operate a pump without a prop-
erly sized pressure relief valve lo-
cated in the flowing discharge line im-
mediately adjacent to the pump dis-
charge connection.
The relief valve should be placed in the flowing dis-
chargelineandnotattheoppositeendofthedischarge
manifoldina dead endconnection. Thedead endmay
become clogged with solid material carried in the fluid,
which could prevent proper relief valve operation.
Never place a shut–off valve or any
other component between the pump
discharge connection and the pres-
sure relief valve.
Make sure the pressure relief valve is installed so any
pressurized relief discharge from the valve is directed
away from possible contact with people or equipment.
The relief valve must be set to relieve at a pressure
equaltoorbelowthemaximumpressurevaluesshown
on the pump data plate. However, if a component is
used in the discharge system with a lower rated pres-
sure capability than that listed on the pump data plate,
thepressurereliefvalvemustbesettorelieveatapres-
sureequalto or belowtherated capabilityofthelowest
rated component.
Before starting the pump every time, check to in-
sure:
SThe pressure relief valve is in good operating
condition and has been set to the proper relief
pressure.
SAny pipe line used to direct pressurized relief
flow to another location, such as a collecting
tank, is not blocked.
SThedischarge systemisnotblockedand allthe
discharge line valves are open.
Check all fluid end discharge system components
including pipe, connections, elbows, threads, fas-
teners, hoses, etc., at least once every six months
to confirm their structural adequacy. With time,
wear, corrosion and fatigue can reduce the strength of
all components. Magnetic iron and steel components
should be checked with magnetic particle or dye pene-
trantcrackdetectionequipment. Nonmagneticmateri-
als should be checked for cracks with dye penetrants.
All metallic components should also be visually
checked during these inspections for signs of corro-
sion. If a component shows evidence of cracking or
loss of material due to corrosion it must be replaced
with a new part.
Continually monitor suction and discharge hose as-
semblieswhenthepumpisoperatingforleakage,kink-
ing, abrasion, corrosion or any other signs of wear or
damage.

3–600 Page 4
Worn or damaged hose assemblies should be re-
placed immediately. At least every six months ex-
amine hose assemblies internally for cut or bulged
tube, obstructions and cleanliness. For segment style
fittings,besurethatthehosebuttsupagainstthenipple
shoulder, the band and retaining ring are properly set
and tight and the segments are properly spaced.
Check for proper gap between nut and socket or hex
and socket. Nuts should swivel freely. Check the lay-
line of the hose to be sure that the assembly is not
twisted. Cap the ends of the hose with plastic covers
to keep them clean until they are tested or reinstalled
on the pump unit. Following this visual examination,
thehose assemblyshouldbehydrostaticallytested,on
teststandshavingadequateguardstoprotecttheoper-
ator, perthehose manufacturer’sprooftestprocedure.
Fluid end component inspections should be per-
formed more frequently than every six months if
pressures above 2500 psi are used in the dis-
charge system or if corrosive, flammable or hot
(over 110_F) fluids are being pumped.
Proper stuffing box packing selection is important for
safe pump operation. Contact a Gardner Denver Ma-
chinery service representative for assistance in select-
ing the proper packing before beginning operation.
Before starting the pump for the first time and periodi-
callythereaftercheck the pump,suctionand discharge
system fastener torques versus the values listed in the
Operating and Service Manual tables to insure proper
tightness. Over and under torquing can damage
threadedpipes,connections andfasteners,which may
lead to component damage and/or failure. Replace all
components found to be damaged or defective. On
pumpsequippedwithstuffingboxes,theglandmustbe
engaged by at least three (3) threads to hold the dis-
charge pressure of the pump.
Do not attempt to service, repair, ad-
just the plunger packing or otherwise
work on the pump while the unit is op-
erating. Shut off the pump drive mo-
tor or engine and relieve the fluid
pressure in the pump suction and dis-
charge systems before any work or
investigation is performed on the
pump or pump systems.
Blockthecrankshaftfromturningandmakecertainthat
all pump drive motor or engine start switches or starter
controls are clearly tagged with warnings not to start
the pump while repair work is in process.
Whenever the pump is operating, continually monitor
theentiresuction, discharge andpumplubricating sys-
tems for leaks. Thoroughly investigate the cause for
leakage and do not operate the pump until the cause
of the leak has been corrected. Replace any parts
which are found to be damaged or defective. When a
gasketed joint is disassembled for any reason, discard
theusedgasketandreplaceitwithanew,genuineGar-
dner Denver gasket before reassembling the joint.
Due to the high working pressures contained by the
fluidcylinder,dischargemanifoldanddischargepiping,
welding on these components is not recommended. If
welding on the discharge system cannot be avoided,
onlyexperienced,qualifiedweldersshould beused. In
addition, the welded part should be hydrostatically
proof tested in the shop with water or hydraulic fluid to
one and one half times maximum discharge system
workingpressure,withnoobservablefluidleakage,be-
fore the part is reinstalled in the pump system.
In summary, high pressure fluid streams can possess
sufficientenergytocause personalinjury,deathand/or
equipment damage. These results can occur either
through direct contact with the fluid stream or by con-
tact with loose objects the fluid stream has propelled,
if the pump system is improperly used, or if the fluid is
misdirected,orallowed to escape fromdefectiveor im-
properly maintained equipment.
FLAMMABLE, HOT, COLD OR CORROSIVE FLUID
PUMPING
Extreme caution must be exercised
by trained and experienced operators
when flammable, hot, cold or corro-
sive fluids are being pumped, in order
to avoid personal injury, death and/or
equipment damage due to explosion,
fire, burn, extreme cold or chemical
attack.
Neveroperate apumpwhichispumpinghydrocarbons
or other flammable, hot, cold, or corrosive fluids when
any part of the pump, suction system or discharge sys-
tem is leaking. Stop the pump immediately if any leak-
age, other than a few drops per minute of packing
weepage, is observed. Keep all flame, sparks, or hot
objects away from any part of the pump, suction sys-
tem, or discharge system. Shield the pump, suction

3–600 Page 5
system and discharge system to prevent any flam-
mable,hot,coldorcorrosivefluidleakagefromdripping
or spraying on any components, flame, sparks, hot ob-
jectsorpeople. Inspecttheplungers,packing,gaskets
and seals for fluid leakage frequently and replace all
worn or leaking parts.
Selection of the proper gaskets, seals and stuffing box
packingisevenmorecriticalwhenflammable,hot,cold
or corrosive fluids are being pumped than when other,
inherently less dangerous fluids are used. Contact a
Gardner Denver Machinery service representative for
assistance in selecting the proper gaskets, seals and
packing before beginning operation.
Sincesomepackingweepageintothecradleareaisin-
evitable, the drain at the bottom of the cradle must be
connected to a drain line which conducts the fluid leak-
age to a collection container located in a protected
area. The entire drain system and container must be
constructed of materials resistant to attack from the
pumped fluid or from explosion or fire of the pumped
fluid. Heavy duty cradle covers must be securely
fastened in the proper position on the pump at all
times when the pump is operating. If the pumped
fluid releases harmful, explosive or flammable va-
pors the covers must be vented to conduct the
fumes away from the pump unit to a nonhazardous
area.
Before beginning pumping operations or starting the
pumppowersource (whether an engineorelectric mo-
tor) check the atmosphere all around the pumping site
for the presence of flammable or explosive vapors. Do
notbeginoperation and stopongoingoperation if flam-
mable or explosive vapors are detected. Hot surfaces,
sparks, electric current or engine exhaust could ignite
flammable or explosive vapors. Each engine used as
a power source on pumping units where flammable or
explosive vapors could form should be equipped with
an air inlet shut–off. If flammable or explosive vapors
arepresentin the pumping siteatmosphere,an engine
couldcontinuetorunonthesevaporsevenaftertheen-
gine fuel line is shut–off if an air inlet shut–off is not
used.
Inaddition,onpumpingunits usedwhereflammable or
explosivevaporscouldform,allelectricmotorsusedas
powersourcesmust be ofexplosionproof construction
andall electricalcomponentsandwiringmustmeetthe
current National Electrical Code for explosive atmosp-
heres.
Theseprecautionsmustbetakentoavoidpossibleper-
sonal injury, death and/or equipment damage from ex-
plosion, fire or burns.
HIGH PRESSURE LIQUID JETTING, BLASTING
AND CLEANING
Extreme caution must be exercised if
any type of wand, gun, nozzle or any
other pressure and flow directing de-
vice is attached to the pump dis-
charge system for use in jetting,
blasting, cleaning, etc. This type of
equipment must be used with utmost
care by trained, experienced opera-
tors. High pressure fluid streams can
either by direct contact or by propel-
ling loose objects, cause serious per-
sonal injury or death to the operators
and/or other persons.
Pressure or flow directing devices often receive pres-
surized flow through flexible hoses, which can burst if
they are kinked, cut, abraded or are otherwise worn,
damagedorpressuredabovetheirratedcapacity. Pro-
tectthehoseandconnectionsfromdamagebypeople,
objects and vehicles. A broken, cut or otherwise burst
hose can release pressurized fluid which may cause
personal injury, death and/or equipment damage.
High pressure fluid from hand held or hand directed
pressure and flow directing devices may overpower an
operator’s ability to control or direct the device, which
could lead to personal injury, death and/or equipment
damage. The operator must brace against the back-
ward thrust of a hand held device. In addition, a safety
harnessor safetynetmust beused whenworkingin an
areawheretheoperatorcouldbeinjuredinafall. Stand
to the side of any tubing or container being sprayed to
avoidbacksprayandneveroperateahandhelddevice
above shoulder level.
Never direct the pressurized fluid stream at yourself or
any other person, control valves, the pump, pump
drive, suction or discharge systems. The pressurized
stream can cause serious personal injury or death and
can also change valve or control settings which could
dangerouslyincreasethedeliverypressuretothepres-
sure and flow directing device.
When operating a pressure and flow directing device,
use only equipment which automatically shuts off flow
whenanoperatorreleaseshandorfootpressureonthe
pressurized flow trigger control to prevent injury if the
operator is overpowered or becomes disabled.
Check to insure this automatic shut–off equipment is
operating properly before every use and never circum-

3–600 Page 6
vent the automatic shut–off for any reason or by any
means when operating the equipment.
Whenoperatinganytypeofhighpressureliquidjetting,
blastingor cleaningdevicestheoperatorsmust always
wear protective clothing including, but not limited to, a
hard hat with full face visor, heavy duty rain coat and
pants, boots with nonskid sole and safety toe, rubber
gloveswithroughgripsurfaceandearnoiseprotection.
Fulloperatorattentionandalertnessarerequiredwhen
operatingthisequipmenttoavoidpersonalinjury,death
and/or equipment damage. The operators should take
frequent rest breaks and cease operations when they
become tired or distracted.
Beforetheequipment isstarted,the workareamust be
inspectedandproperlypreparedtoavoidpersonalinju-
ry, death and/or damage to equipment. Make sure the
work area is checked for hazardous fumes, has ade-
quate ventilation for engine exhaust and sufficient
drainage for released fluid. Check the work area for
electrical equipment, connections, outlets, fixtures, or
lines. If any are present they must be made water tight
and the electrical power to these devices must be shut
off to avoid electrical shocks from fluid contact. The
work area should be clearly marked and roped off to
keep unauthorized people and vehicles from entering.
Remove all loose parts, tools and equipment from the
work area before beginning operation.
All pressure containing devices including wands,
nozzles,guns,hoses,connections,etc.,shouldbereg-
ularly checked for condition. These components
shouldallbetaggedwiththeirtestedpressurecapabili-
ties together with the date testing was performed. Al-
ways be aware of the pressure level in the system
and never connect any equipment to the system
which has a rated or tested pressure capability be-
low the system operating pressure. The equipment
must be shut down and the system pressure released
before changing or disconnecting wands, nozzles,
guns, hoses, connections or any other pressurized
system components.
All pressure containing devices including wands,
nozzles, guns, connections, etc., plus all automatic
shut–off, pressure and control equipment should be
treated with care. Protect them from damage by
people, objects and vehicles. Never lay them in dirt,
mud, ice or other loose material which could plug the
fluid opening or interfere with their operation. Never
usethewand, nozzle,gun, etc.topry loosematerialoff
items being cleaned.
Before starting operation in a cold environment, check
to make sure there is no ice in the fluid system and re-
peat this inspection each time before operation is re-
started.
Beforepurchasingwands,nozzles,guns,connections,
and hose, etc., manufacturers of these components
should be contacted for detailed information on the de-
sign 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 pur-
chase that you judge to offer the highest quality of de-
sign, construction and safety, since these components
areamongthemostcriticaltothesafeoperationofhigh
pressure liquid jetting, blasting and cleaning equip-
ment.
After you have selected and purchased these compo-
nents,followthemanufacturer’sinstructionscomplete-
ly in their use.
In summary, high pressure jetting, blasting and
cleaning are inherently dangerous, as the pressur-
es 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.

3–600 Page 7
SECTION 2
INSTALLATION & OPERATING INSTRUCTIONS
FOR GARDNER DENVER FXF, FXG, FXX, FXD and FXE DUPLEX POWER PUMPS
INSTALLATION – The pump should be installed as
close to the fluid supply as possible. Whenever pos-
sible, ample space should be provided around the
pump to facilitate inspection and adjustment with par-
ticular attention to the space required for removal and
installation of piston rods, liners and jackshafts.
Pump should be properly leveled and securely fas-
tened to whatever type of foundation is provided.
The drive must be accurately aligned.
PIPING
All piping must be supported inde-
pendently of the pump to insure that
no strain is imposed on the pump by
misalignment or improperly fitted
pipe.
Fluid Inlet or Suction Piping – Inlet piping should be
as direct and short as possible and should be laid out
so that air pockets are eliminated. The inlet pipe must
never be smaller than the pump inlet and lines longer
than 20 feet (6 meters) (including friction) must never
beexceeded. To protectthepump fromforeignmatter,
an inlet strainer should be installed with a net area of
four times the inlet pipe.
Fluid Discharge Piping –Itis advisable tousean am-
ple size discharge line to prevent excessive friction.
Theuseofan air chamber is recommendedandample
size chambers are available for all pumps.
RELIEF VALVE – Pump must be protected from ex-
cesspressurebyadischargepressurereliefvalve.The
valvemustbeinstallednearthepump,preferablyinthe
opening provided for it in the discharge manifold on
models where applicable. Never install a shutoff valve
in the line between the relief valve and pump cylinder.
The relief valve should be set to operate at approxi-
mately 1–1/4 times the discharge pressure, but must
not exceed system equipment tolerances.
CRANKCASE OIL REQUIREMENTS
Crankcase
API–GL5 Ambient Operating Oil Minimum Startup
Oil Grade Temperature Temperature * Oil Temperature
75W–90 –20_F to 90_F60_to 170_F20_F
(–29_C to 32_C) (16_C to 77_C) (–7_C)
80W–140 10 F to 120 F 90_F to 200_F50_F
(–12_C to 49_C) (32_C to 93_C) (10_C)
80 –10_F to 60_F70_F to 140_F30_F
(–23_C to 16_C) (21_C to 60_C) (–1_C)
90 20_F to 100_F 100_F to 180_F60_F
(–7_C to 38_C) (38_C to 82_C) (16_C)
140 50_F to 120_F 130_F to 200_F80_F
(10_C to 49_C) (54_C to 93_C) (27_C)
* An 80_F (27_C) crankcase oil temperature rise over ambient air temperature is typical
for the pumps covered by this manual when operating at or near rated horsepower.
FIGURE 1 – CRANKCASE OIL REQUIREMENTS

3–600 Page 8
Improper use or maintenance of relief
valves can cause excessive pressure
which may result in property damage
and/or serious personal injury or
death.
When the pump is equipped with Shear Type Relief
Valve,use onlyone ShearPinofthesizeshownonthe
settingplate.Theuseofanailoranysheardeviceother
than Vendor Shear Pin may be extremely hazardous.
Do not hammer on shear bar or stem or shear bar slot.
LUBRICATION – Recommended crankcase oils are
as shown in FIGURE 1, page 7.
Oil viscosity must not exceed 7000 SSU at startup and
mustbebetween1500SSUand130SSUwhileoperat-
ing, regardless of the oil temperature or grade used. A
crankcase heater and/or an oil heat exchanger may be
needed to meet these requirements.
Failuretofollowtheselubricationrequirementswillvoid
the warranty.
The approximate quantities of lubricant required to
properly fill the crankcases of each size pump are as
follows:
Stroke Power U.S Imperial
Inches mm End Gallons Gallons Liters
5 127 FXF 3 2–1/2 11–1/2
6 152.4 FXG 4–1/2 3–3/4 17
8 203.2 FXX 12 10 46
10 254 FXD 14 11–3/4 53
10 254 FXE 14 11–3/4 53
FIGURE 2 – LUBRICATION FILL RATE
Oil must be added as required to maintain the level to
thetopof the street elbowinthe end oftheframe.Time
between oil changes depends upon local conditions.
However, if crankcase is kept closed, it should not be
necessary to change oil any more than each 1000
working hours.
Jackshaftandeccentricshaftrollerbearingsaresealed
off from the crankcase lubricant and are provided with
pressure gun grease fittings. A reliable multipurpose
FIGURE 3 – PACKING TYPE PISTON
grease NLGI Grade No. 2 should be supplied to these
with discretion. Roller bearings WILL HEAT IF TOO
MUCH GREASE is used, especially if bearing is com-
pletely filled with grease.
FLUIDPISTONSANDPACKING–Fourgeneraltypes
offluidpistonsandpackingsareused,dependingupon
operating conditions or requirements. The pumps are
packed at the factory complete.
Low Pressure Water or Boiler Feed Service – For
low pressure water or boiler feed service, use iron or
bronze follower type pistons with fibrous duck and rub-
berringshavingregularorrockhardcure.Regularcure
rings are recommended for fluids with temperatures of
180_F (82.2_C) or lower. Rock hard rings should al-
ways be used for fluids with higher temperatures to
250_F (121.1_C) maximum. Ring lateral clearance
between the follower and piston body flange is deter-
mined by the amount of packing. Clearance should be
1/16” (1.5875 mm) for 3” (76.2 mm) width packing and
under, and 1/8” (3.1 75 mm) for width beyond 3” (76.2
mm). The rings should be installed with the end step–
cutjointgapof1/32”(.7937mm)for3”(76.2mm)diam-
eter and under, 1/16” (1.5875 mm) for 3” (76.2 mm) to
7–1/2”(190.5mm),and1/8”(3.175mm)beyond7–1/2”
(190.5 mm) diameter. All regular cure and rock hard
pistonpackingshouldbe soaked at leasteighthoursin
warm water before installing.
HighPressureSpecial FluidService –Forhighpres-
sure water and mildly abrasive fluids, the cup type pis-
tons are recommended. Pistons are available in
bronze, steel, iron, monel and stainless steel. Fluids
such as acids and alkalis require special cup composi-
tions and should be referred to factory for information.
To assemble the piston to the rod, proceed as follows:
1. Mount the hub to the taper.

3–600 Page 9
FIGURE 4 – CUP TYPE PISTON
Temperature Pressure Texture
–20_F to 212_F 0 to 125 PSI Soft
(–28.9_C to 100_C) (0 to 8.79 kg/cm2)
–20_F to 300_F 100 to 500 PSI Medium
(–28.9_C to 148.9_C) (7.03 to 35.15 kg/cm)
30_F to 300_F 500 to 1000 PSI Hard
(–1.1_C to 148.9_C) (35.15 to 50.31 kg/cm)
FIGURE 5 – PISTON TEXTURES
2. Fit cup snugly to the hub.
3. Mount the spacing plate.
4. Mount the outer cup.
5. Mount the follower plate and tighten the nut and
locknut securely.
For the texture of the cups, see FIGURE 5.
Clean Oil or Petroleum Products Service (All Pres-
sures) – Solid metal pistons with grooves and metal
snap rings or non–metallic rings with expanders are
recommended. Piston ring grooves have the proper
clearance but it is necessary to check rings for end
clearance. Insert each ring in the cylinder liner and
check end clearance with a feeler gauge. Metal rings
should have from .003” (.076 mm) to .004” (.1 02 mm)
per inch (25.4 mm) of ring diameter and nonmetallic
should have from .006” (.152 mm) to .008” (.203 mm)
per inch (25.4 mm) of ring diameter.
High Pressure Pistons For Abrasive Service – For
high pressure slush service or mud with abrasive par-
ticles, a regular oil field rubber type piston is recom-
mended.
High Temperature Service – Consult the Factory for
recommendations.
Fluid Piston Rod Packing – Braided synthetic pack-
ingis standardforwater,oiland generalservice. Maxi-
mum service ratings for this packing are 250 PSI and
250_F.
Molded convex packing is standard for mud service.
Maximum rated service temperature is 180_F.
Molded rubber and duck packing is standard for grout
and cement service and optional for other services.
Maximum rated service temperature is 250_F.
Rod packings should always be installed in a clean
stuffingbox.Eachringshouldbefirmlyseatedbytamp-
ing as it is applied. When box is full, gland nuts should
be tightened with a wrench just enough to seat the
packing properly; then slacken off and tighten nuts by
hand, locking the gland with a final quarter turn with a
wrench. DO NOT TIGHTEN GLANDS TOO TIGHT.
Some fluids require special packing and should be re-
ferred to the factory.
Fluid Piston Rod Baffle –Allpumpsare supplied with
an oil resistant rubber baffle which is mounted on the
piston rod between the piston rod stuffing box and the
oil stop head. The baffle must be kept in place to pre-
ventforeignmaterialfollowingalongthepistonrodfrom
the stuffing box into the power end.
Warranty is void if this baffle is not in
place.
Frame Oil Stop Head Packing – Oil stop head pack-
ing is cut square fibrous rings. The packing should be
inspected frequently and adjusted if necessary. Re-
place when worn.
Fluid Cylinder Liner Packing – Current liner packing
construction consists of two ”square rubber hydraulic
rings”withametalspacerbetweenthemandissuitable
for most services.

3–600 Page 10
Never tighten liner jack screws while
pump is running. If the screws are
drawn up too tight, enough pressure
can be put on thepacking to crushthe
liner. This ruins the liner, is apt to ruin
the piston and can cause piston rod
breakage.
Wheneverthecylinderheadisremovedforanyreason,
the liner jack screws must be backed out. Jack screws
should be greased to increase life of screws and cylin-
der heads and also to prevent rust formation.
When the cylinder head is replaced, the head to cylin-
der stud nuts should be tightened completely. AFTER
the head nuts are tight, the liner jack screws should be
adjusted against the liners and the locknuts tightened.
Besurepackingisinstalledundersetscrewnutstopre-
vent leakage
Some pumps are equipped with a clamp located
against the end of the liner and serves as a face for the
set screws to bear against. For the proper tightening
torques refer to torque table, page 18.
FLUIDENDPARTS –Standardprocedureforshipping
pumps from the Factory is with valves, pistons, liners,
piston rods and packing installed. These fluid end ex-
pendable parts are shipped unassembled only when
requested by the customer.
FLUID CYLINDER LINERS – Liners should be
installed in accordance with instructions given under
heading ”Fluid Cylinder Liner Packing”, page 9. Clean
liners thoroughly and grease the outside diameter be-
foreinstalling.Linerjackscrewsshouldbetightenedas
uniformly as possible.
PISTON RODS – Pistons should be assembled on the
rod taper WITH THE THIN NUT NEXT TO THE PIS-
TON HUB AND THE THICK NUT ON THE OUTSIDE.
Thisisimportantastheouternutcarriestheload.Slush
service rods use one elastic collar–type locknut per
rod. Rods should be threaded into the crosshead as
shown in FIGURE 6, leaving approximately one thread
of the locknut over the relieved portion of the rod as a
protection to the threads.
FLUID VALVES – Valves areeasilyinstalledintheir in-
dividualvalvepots.Careshouldbeexercisedtotighten
the valve cover nuts as uniformly as possible, tighten-
ing each nut a little at a time until all are tight. Valve
FIGURE 6 – PISTON ROD
seats and the bore in the deck must be perfectly clean
and free from oil or grease.
Valve seats can be removed with a puller which can be
purchased from Gardner Denver Machinery Inc.
STARTING A NEW PUMP – Pumps are shipped from
the factory without oil in the crankcase. The hood
should be removed and the power end examined and
cleanedifnecessary.Thepumpmayhavebeeninstor-
ageorin the yardforsome time andasaconsequence
dirt may have entered the crankcase. Parts may have
been robbed from the pump during storage and not re-
placed. All nuts and screws should be tightened.
Thejackshaftbearingshavebeensuppliedwithgrease
at the factory and no grease should be added at this
time, unless bearings have been disturbed.
Be sure all valves in the discharge line are open. No
valve should be installed between the pump and pres-
sure relief valve in discharge line.
To prevent excessive wear on the fluid pistons and
packing when starting, remove a suction valve cover
plateoneachsideof the fluid end and primethepump.
Pump should be started slowly, if possible, and should
be operated for several hours with practically no dis-
charge pressure. Check oil level as it may be neces-
sarytoaddasmallquantityofoiltocompensateforthat
adhering to the walls of the crankcase and the moving
parts. The pump may then gradually be brought up to
full speed and full working pressure. Watch for undue
heating or abnormal noise in the working parts. Check
all joints in the suction line to be sure there are no air
leaks.
Make certain pump is rotating in the correct direction.
Refer to FIGURE 7, page 11.

3–600 Page 11
FIGURE 7 – ROTATION OF ECCENTRIC
PREFERRED ROTATION OF ECCENTRIC

3–600 Page 12
SECTION 3
ROUTINE MAINTENANCE & SERVICE INSTRUCTIONS
FIGURE 8 – JACKSHAFT ASSEMBLY
Daily Care – The pump should be kept clean, lubri-
catedproperlyandstuffing boxesexamineddaily.With
reasonable care, the pump can be expected to give
long and trouble–free life.
Occasional Inspection – It is recommended that the
fluid valves be examined occasionally to see that ex-
cessivewearorcuttinghasnotimpairedtheirefficiency
and any damaged or worn parts should be replaced.
Fluid end must always be drained when exposed to
freezing weather during idle periods.
SERVICE INSTRUCTIONS
Removal of Jackshaft – To remove the jackshaft, it is
necessary to remove the bearing housings from both
sides of the pump. The bearing outer races and rollers
come off with the housings. The bearings inner races
andthesealbushingsarepressedonthejackshaftand
neednotberemovedunlessreplacementisnecessary.
The jackshaft can be lifted clear of the gear teeth and
removed. The jackshaft is not interchangeable end for
end, hence, it must be reinstalled in the same way it
was removed.
Installation of Jackshaft Oil Seals – The jackshaft
roller bearings are provided with a separate inner and
outer oil seal. The correct assembly of these seals is
with seal lips facing bearings.
To Remove Crosshead Pin From FXF and FXG
Pumps – The crosshead pin can be removed from the
FXFandFXGonly by removing theentiregearassem-
bly. To remove the gear and eccentric, it is necessary
to remove the main shaft. The main shaft must be re-
movedfromthesideofthepumpinwhichtheendofthe
shaft contains a 3/4–10 UNC tapped hole. This is the
end of the shaft that also contains the main shaft to ec-
centric key. (See FIGURE 9.) It is advisable to have
new shaft seals as these seals can rarely be used the
FIGURE 9 – ECCENTRIC AND MAIN SHAFT ASSEMBLY

3–600 Page 13
FIGURE 10 – CROSSHEAD PIN REMOVAL–FXX, FXD & FXE
A41503
second time. Remove shaft through eccentric with
hammerandwoodblockandthebearingconeandseal
bushingonthesideoppositethetappedholewillslipoff
the shaft.
The gear assembly with connecting rods and cross-
heads can all be pulled out through the hood opening
afterthemainshafthasbeenremoved.Thepistonrods
of course must be screwed out of the crossheads be-
fore the assembly can be taken from the frame. Cross-
headpinsarestraightandareheldinplaceinthecross-
heads with set screws.
To Remove Crosshead Pin From FXX, FXD and
FXEPumps–Theinspectionplateson thesidesofthe
frame should be removed. Two hexagon head cap
screwsare usedtoholdthecrossheadpintothecross-
head. These are the two screws in the corners of the
plate over the crosshead pin. Take these screws out
andinsertthem in thetappedholes intheadjacentcor-
ners of the plate and by exerting sufficient pressure
with these screws the crosshead pin will come out. A
little persuasion with a drift driven against the cross-
head near the outer end of the crosshead pin will help.
To remove the gear and eccentric it is necessary to re-
move the main shaft and piston rods. The main shaft
mustberemovedfromthesideofthepumpinwhichthe
shaft contains a 3/4–10 UNC tapped hole. This is the
end of the shaft that also contains the main shaft to ec-
centric key. (See FIGURE 9, page 12.) Support eccen-
tric on blocking and drive shaft through eccentric with
hammer and wood block. The bearing cone and seal
sleeve,onthesideoppositethetappedhole,willslipoff
the shaft.
To Install Main Bearings For All Pumps –
1. Install eccentric with gear teeth in correct position
in frame.
2. Install main shaft through opening in frame and
through eccentric.
3. Heat and press bearing cones to shaft.
4. Install bearing cups.
There should be no space between
the bearing cones and seal bushing
or between the seal bushing and ec-
centric hub.
5. Install gasket and end plate on one side.
6. Take up end plate on other side snugly with cap
screws.
7. Check the gap between plate and frame housing
with shims. Determine shims required to fill the
gap. When you have determined the shims re-
quiredtofillthegap,remove0.001to0.003inches
(0.0254 to 0.0762 mm) of shims.
8. Remove end plate and install remaining shims.
9. Mount and secure plate.
FXE Main Gear and Eccentric – This pump is
constructed with a separate gear bolted to the eccen-
tric. Refer to page 18 for screw torque specifications.
MAINTENANCE OF SPARE REPAIR PARTS – Al-
thoughoperatingconditionsvarywidely,itissuggested
that a stock of spare replacement parts be maintained
to insure against loss of pump operation. It is consid-
ered good practice to keep spare fluid valves, pistons,
pistonrods,packings, gaskets,etc.on hand. Arecom-
mended list of such parts may be secured from Gard-
ner Denver Customer Service, the Master Distribution
Center (MDC), or your local authorized Gardner Den-
ver Distributor.
ORDERING OF REPAIR PARTS – Repair parts lists
withsectionalviewsareavailableforanyGardnerDen-
verpower pump and may be secured from Gardner
Denver Customer Service, the Master Distribution
Center (MDC), or your local authorized Gardner Den-
ver Distributor.

3–600 Page 14
When ordering parts lists or repairs, always give size
and serial number of pump. Serial number is stamped
on the pump nameplate attached to frame and also on
a raised pad located on upper side of the power frame
at the fluid cylinder end.
Iftheserialnumbercannot beidentified,obtain several
photographic views of the power frame and fluid cylin-
ders, including part numbers of principal castings
which should furnish us clues as to the identity of the
pump.
SPECIALCAREOF PUMPIN STORAGE –Pistonrod
packing and piston packing must be removed, if the
pump is not put in service immediately. Permitting
packing to remain in an idle pump for a period of time
will tend to create rusting and pitting of liner bore and
piston rods.
Puller kit parts for removing valve seats, liners and
crosshead pin bushings may be purchased from Gard-
ner Denver Machinery Inc.
OPERATING SPEEDS AND PRESSURES – See bul-
letins for operating speeds and pressures for type of
service.
All displacements are theoretical with piston rod vol-
ume deducted. For actual delivery deduct from 5% to
10% for slippage using 10% at maximum RPM.
Pressures are maximum permissible
with rated maximum piston rod loads
and MUST NEVER BE EXCEEDED.
While it is true that reducing the speed reduces the
horsepower practically in direct proportion, the piston
load for which the pump is designed is a function of the
fluid pressure against the piston. Reducing the speed
to half and doubling the pressure requires approxi-
mately the same horsepower but results in 100% over-
load on the power end.
Maximum input BHP and shaft RPM shown in bulletins
MUST NEVER BE EXCEEDED under any operating
conditions. These speeds are recommended for favor-
able suction conditions and consideration must be giv-
en to viscosity and character of fluid.
DO NOT operate these pumps below
40 RPM as this will hinder proper lu-
brication.