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`GARDNER DENVER®
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` 400TLS996 Rev B
`August 2013
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`DRILLING PUMP
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`MODEL
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`MAVERICK
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` OPERATING AND
` SERVICE MANUAL
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`ECN 1077541
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`Page 1 of 52
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`GARDNER DENVER®
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` 400TLS996 Rev B
`August 2013
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`DRILLING PUMP
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`MODEL
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`MAVERICK
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`
` OPERATING AND
` SERVICE MANUAL
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`ECN 1077541
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`Page 2 of 52
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`

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`MAVERICK
`
`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 are incorporated in
`our genuine replacement parts.
`
`Your authorized Gardner Denver distributor 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 inventory of genuine parts and he is backed up for emergency parts issues
`with access to Oklahoma City, OK and the factory in Quincy, IL.
`
`Your authorized distributor can support all your Gardner Denver pump needs.
`
`Trained parts specialists are available to assist you in selecting the correct replacement parts.
`
`ALL ORDERS for PARTS should be placed with the NEAREST Authorized Distributor.
`
`To find your nearest distributor you may use one of the following choices:
`* Log onto the Gardner Denver web site: www.pumpingperfected.com
`* Send an E-Mail request to: pumps@gardnerdenver.com
`* Contact one of our sales offices listed below.
`
`The Gardner Denver Sales Offices are located as follows:
`
`
`DOMESTIC
`Gardner Denver
`2200 South Prospect
`Oklahoma City, OK. 73129
`
`Phone: (405) 677-5736
`
`Fax: (405) 677-5807
`
`INTERNATIONAL
`Gardner Denver
`1800 Gardner Expressway
`Quincy, IL 62305
`
`Phone: (217) 222-5400
`
`Fax: (217) 223-1581
`
`
`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).
`
`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 parentheses. SPECIFY THE NUMBER OF PARTS REQUIRED, EXACTLY.
`
`DO NOT ORDER BY SETS OR GROUPS.
`
`To determine the Right Hand and Left-Hand side of a pump, stand at the power end and look toward the fluid
`end. Right Hand and Left Hand are indicated in parenthesis following the part name, i.e. (RH) and (LH),
`when appropriate.
`
`400TLS996 Page i
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`Page 3 of 52
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`

`

`FOREWORD
`
`
`
`the result of advanced engineering and skilled
`Gardner Denver® pumps are
`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.
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`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.
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` DANGER
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` WARNING
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`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.
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` CAUTION
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`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.
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`NOTICE
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`Notice is used to notify people of installation, operation or maintenance
`information which is important but not hazard related.
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`400TLS996 Page ii
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`Page 4 of 52
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`

`

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`TABLE OF CONTENTS
`
`Maintain Pump Reliability and Performance .............................................................................. i
`
`Instructions for Ordering Repair Parts ........................................................................................i
`
`Foreword .....................................................................................................................................ii
`
`List of Tables and Figures ..........................................................................................................iv
`
`Section 1: Danger Notices ..........................................................................................................1
`
`Section 2: Design Concept, Description and Specifications ...................................................... 9
`
` Introduction ...........................................................................................................................9
` Pump Design ........................................................................................................................10
` Power End ............................................................................................................................10
` Gear Reduction Unit .............................................................................................................11
` Power End and Gear Reduction Unit Lube System .............................................................11
` Fluid End ...............................................................................................................................12
` Liner Clamps and Liners .......................................................................................................13
` Pistons and Piston Rods ......................................................................................................13
` Piston/Rod Washing System ................................................................................................13
` Oil Stop Heads......................................................................................................................13
` Suction Strainer ....................................................................................................................14
` General Specifications ..........................................................................................................14
`
`Section 3: Preparation, Operation and Maintenance .................................................................15
`
` Preparation after Shipping & Storage ...................................................................................15
` Pump Mounting Instructions .................................................................................................15
` Power End Lubrication System ............................................................................................16
` Piston/Rod Washing System ................................................................................................18
` Startup and New Pump Run-in Procedures .........................................................................18
` Periodic Routine Maintenance Schedule .............................................................................19
` Liner Clamp and Liners ........................................................................................................21
` Pistons and Piston Rods ......................................................................................................21
` Maintenance of Valves .........................................................................................................22
` Oil Stop Heads......................................................................................................................22
` Extension Rods ....................................................................................................................24
`
`Section 4: Service Procedures ...................................................................................................25
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` Fluid End Service .................................................................................................................25
` Power End Service ...............................................................................................................28
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`Section 5: Troubleshooting .........................................................................................................32
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`Section 6: Rebuilding Data, Recommended Running Clearances and Torques .......................38
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`Appendix A: Superbolt Installation and Removal Instructions ....................................................40
`
`Product Warranty ........................................................................................................................44
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`400TLS996 Page iii
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`Page 5 of 52
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`

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`Figure # Description
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`Figure 2-1
`
`LIST OF TABLES & FIGURES
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`Page
`
`Maverick Pump ......................................................................................... 9
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`Figure 2-2
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`Maverick Power End ................................................................................. 10
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`Figure 2-3
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`Maverick Gear Reduction Unit .................................................................. 11
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`Figure 2-4
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`Maverick Fluid End .................................................................................... 12
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`Table 1
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`General Specifications .............................................................................. 14
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`Table 2
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`Sizes and Ratings ..................................................................................... 14
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`Figure 3-1
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`Typical Lubrication Schematic .................................................................. 17
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`Figure 3-2
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`Lubricant Recommendations .................................................................... 17
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`Figure 3-3
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`Rod Wash Manifold Feeding Urethane Shrouds ...................................... 18
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`Figure 3-4
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`Liner Installation ........................................................................................ 21
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`Figure 3-5
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`Two Piston and Piston Rod Assemblies ................................................... 21
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`Figure 3-6
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`Oil Stop Head Seals Installed ................................................................... 22
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`Figure 3-7
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`Two Extension Rods ................................................................................. 23
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`Figure 4-1
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`Tightening Sequence for Fluid End Nuts .................................................. 25
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`Figure 4-2
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`Suction Manifold Installation ..................................................................... 25
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`Figure 4-3
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`Rod Wash Manifold & Shrouds ................................................................. 26
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`Figure 4-4
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`P-Quip Kwik-Rod System .......................................................................... 26
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`Figure 4-5
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`Falcon Spring Retainer ............................................................................. 28
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`Figure 4-6
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`Crosshead and Connecting Rod Assembly .............................................. 29
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`Table 3
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`Rebuilding Data for Maverick Pump ......................................................... 38
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`Table 4
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`Recommended Running Clearances – Actual .......................................... 38
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`Table 5
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`Recommended Torque Values for Maverick Pump .................................. 39
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`400TLS996 Page iv
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`Page 6 of 52
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`

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`injury. The original parts used in Gardner
`Denver pumps are designed and tested to
`exacting standards to provide high quality
`performance and durability.
` Your best
`insurance
`in
`maintaining
`these
`characteristics is to use genuine Gardner
`Denver replacement parts.
`
` A
`
` broad range of danger notices are
`covered on these pages, however they
`cannot substitute for training, experience,
`and common sense in the safe operation of
`high pressure pumping equipment.
`
`
`HAMMER LUG FASTENERS
`
`
` DANGER
`
`
`lug
`On pumps equipped with hammer
`unions 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, broken parts from the hammer,
`lugs or other objects propelled by hammer
`blows.
` When
`tightening or
`loosening
`hammer
`lug unions and valve covers,
`operators or maintenance personnel should:
`
`Inspect the hammer and hammer lugs to
`ensure they are all in good condition.
`Replace any of these parts which are
`cracked, damaged, or badly worn.
`
` •
`
`
`
` •
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` Wear safety shoes and safety glasses.
`
` •
`
` Alert other personnel to move away
`from the area.
`
` •
`
` Check to ensure they have safe footing.
`
` •
`
` Fully engage the hammer bar, if one is
`used, to prevent it from disengaging
`violently from the cover as a blow is
`struck.
`
` •
`
`the hammer
`their hands and
` Wipe
`handle and maintain a firm grip on the
`handle to avoid losing control of the
`hammer while swinging and striking.
`
`SECTION 1
`DANGER NOTICES
`
`
`
` DANGER
`
`
`following
`the
`Read and understand
`DANGER NOTICES before moving or
`operating the pump or any pump package
`unit equipment.
`
`Reciprocating pumps are machines capable
`of producing high fluid pressures and flow
`rates and are designed to be used with
`proper care and caution by
`trained,
`TO
`AVOID
`experienced
`operators.
`PERSONAL
`INJURY, DEATH AND/OR
`EQUIPMENT DAMAGE, READ AND
`THOROUGHLY
`UNDERSTAND
`THE
`FOLLOWING DANGER NOTICES PLUS
`THE ENTIRE OPERATING AND SERVICE
`MANUAL BEFORE ATTEMPTING TO
`MOVE OR OPERATE THE PUMP. Contact
`a Gardner Denver service representative if
`you are unable to comply with any of the
`danger notices or procedures described in
`these documents.
`
`Closely examine the pump performance
`data upon pump delivery
`to become
`thoroughly familiar with the operating limits
`for this pump model. The pump must
`never be operated at speeds, pressures
`or horsepower exceeding the maximum
`values or at speeds below the minimum.
`Failure to observe the operating limits
`could result in personal injury, death,
`and/or equipment damage and will void
`the warranty. Alterations to the pump, or
`application of the pump outside the limits,
`must not be made without Gardner Denver
`written approval, together with a new set of
`performance data, as dangerous operating
`conditions could result.
`
`Keep in mind that full operator attention and
`alertness are required when operating high
`pressure pumping equipment. Operators
`should not begin or continue operations
`when tired, distracted, or under the influence
`of 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
`
`400TLS996 Page 1
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`Page 7 of 52
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`

`

` •
`
` Wipe their hands and the hammer
`handle and maintain a firm grip on the
`handle to avoid losing control of the
`hammer while swinging and striking.
`
` •
`
` Carefully swing the hammer to avoid
`striking themselves, another person and
`objects other than the targeted wedge.
`
` •
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` Avoid swinging the hammer above
`shoulder height.
`
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`COVERS AND GUARDS
`
`
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` DANGER
`
`
`/or
`injury, death and
`Personal
`equipment damage can result from
`contact with moving parts. All
`moving parts must be equipped with
`covers and guards. All covers and
`guards must be securely positioned
`at all times when the unit is in
`operation.
`
`
`Covers and guards are intended to not only
`protect against personal injury or death, but
`to also protect the equipment from foreign
`object damage
`
`
`EQUIPMENT MOVING AND LIFTING
`
`
` DANGER
`
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`Heavy equipment including pumps, pump
`packages, and components should only be
`moved or lifted by trained, experienced
`operators who are physically and mentally
`prepared
`to devote
`full attention and
`alertness
`to
`the moving and
`lifting
`operations. An operator should be fully
`aware of the use, capability, and condition of
`both the equipment being moved and the
`equipment being used
`to move
`it.
`
`
`
` •
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` Carefully swing the hammer to avoid
`striking themselves, another person, or
`objects other than the targeted lugs or
`hammer bar.
`
`the hammer above
`
` •
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` Avoid swinging
`shoulder height.
`
`
`
`VALVE SEAT PULLING
`
`
` DANGER
`
`
`The following precautions must be observed
`by operators and maintenance personnel to
`avoid
`personal
`injury,
`death
`and/or
`equipment damage from contact with the
`puller, hammer, wedge, or broken parts from
`these components when using either a
`hydraulic or a wedge valve seat puller.
`Operators or maintenance personnel should:
`
`Hydraulic Seat Puller
`
` •
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` Wear safety shoes and safety glasses.
`
` •
`
` Chain or tie the jack down, as it will
`jump violently when
`the valve seat
`disengages from the valve deck.
`
` •
`
` Check to ensure the pressure applied by
`the hydraulic pump does not exceed the
`maximum hydraulic ram pressure rating.
`
`
`Wedge Seat Puller
`
` •
`
` Grind off any mushroomed material from
`the wedge before use.
`
`Inspect the hammer and wedge to
`ensure they are in good condition.
`Replace any of those parts which are
`cracked, damaged or badly worn.
`
` •
`
`
`
` •
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` Wear safety shoes and safety glasses.
`
` •
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` Check to ensure they have safe footing.
`
` •
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` Fully engage the wedge to prevent it
`from disengaging violently from the
`cover as a blow is struck.
`
`400TLS996 Page 2
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`Page 8 of 52
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`

`

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` DANGER
`
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`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,
`falling or other unexpected or
`uncontrolled equipment movements.
`
`
`Make sure the hoist, lift truck, ropes, slings,
`spreader bar, or other lifting equipment you
`are using is in good condition and has a
`rated lifting capacity equal to or greater than
`the weight being lifted. Lifting devices must
`be checked frequently for condition and
`continued conformance
`to
`rated
`load
`capacity. They should then be tagged with
`the rated capacity together with the date of
`inspection.
`
`Fully assembled pumps and pump packages
`are heavy and should only be moved using
`the specified lifting lugs or attachments.
`
`Many individual components 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.
`
`individual component,
`the
`lifting
`Before
`check to ensure the lifting attachment is
`firmly secured
`to
`the component with
`undamaged, properly
`torqued
`fasteners,
`sound welds, or other secure attachments.
`Examine the lifting eyes, lugs, slots, holes,
`or other projections to ensure 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.
`
`lifted with
`Package units should be
`the
`lifting
`spreaders
`connected
`to
`attachments normally built into the package
`unit support skid. Packages too large to lift
`
`as fully assembled should be separated into
`smaller loads.
`
`For these smaller loads, the lifting devices
`should be fastened to the lifting attachments
`normally built
`into
`the
`individual motor,
`engine,
`pump,
`transmission/torque
`converter, or their separate support skids.
`
`When lifting subassembled components, for
`example a suction stabilizer attached to
`suction piping or a discharge pulsation
`damper attached to a strainer cross and
`piping, use special lifting slings designed to
`safely support the combined weight of the
`components.
`
`If a crane or hoist is being used to lift large
`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.
`
`When starting to lift a pump, package unit,
`subassemblies, 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 equipment to pass over or close to one’s
`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
`
`
`
` DANGER
`
`
`Fluids under high pressure can
`possess sufficient energy to cause
`personal
`injury,
`death
`and/or
`equipment damage either through
`direct contact with escaping fluid
`streams or by contact with loose
`objects the pressurized fluid propels.
`
`400TLS996 Page 3
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`Page 9 of 52
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`

`

`
`
`
`
`Each time before starting the pump,
`check to ensure:
`• The pressure relief valve is in good
`operating condition and has been set to
`the proper relief pressure.
`
` •
`
` Any pipe line used to direct pressurized
`relief flow to another location, such as a
`collecting tank, is not blocked.
`
` •
`
` The discharge system is not blocked
`and all the discharge line valves are
`open.
`
`
`Check all fluid end discharge system
`components
`including pipes, elbows
`connections, threads, fasteners, hoses,
`etc., at least once every six months to
`confirm their structural adequacy. Wear,
`corrosion and fatigue can, with time, reduce
`the strength of all components. Magnetic
`iron and steel components should be
`checked with magnetic particle or dye
`penetrant
`crack
`detection
`equipment.
`Nonmagnetic materials should be checked
`for cracks with dye penetrants. All metallic
`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
`corrosion it must be replaced with a new
`part.
`
`Continually monitor suction and discharge
`hose assemblies
`for
`leakage, kinking,
`abrasion, corrosion, or any other signs of
`wear or damage when
`the pump
`is
`operating.
`
`Worn or damaged hose assemblies
`should be replaced immediately. At least
`every six months, examine hose assemblies
`internally
`for
`cut or bulged
`tubes,
`obstructions, and cleanliness. For segment-
`style fittings, be sure that the hose butts up
`against the nipple 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 layline 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.
`
`
`
`Operating a pump against a blocked or
`restricted discharge
`line can produce
`excessive pressures in the entire discharge
`system, which can damage or burst
`discharge system components.
`
`
`
` DANGER
`
`
`Never operate a pump without a
`properly-sized pressure relief valve
`or working overpressure shut-down
`in the discharge
`line
`immediately
`adjacent to the pump discharge.
`
`
`The relief valve should be placed in the
`flowing discharge
`line and not at
`the
`opposite end of the discharge manifold in a
`dead end connection. The dead end may
`become clogged with solid material carried
`in the fluid, which could prevent proper relief
`valve operation.
`
`
`
`
`
` DANGER
`
`
`
`Never place a shut-off valve or any
`other component between the pump
`discharge
`connection
`and
`the
`pressure 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 equal to or below the maximum
`pressure values shown on the pump data
`plate. However, if a component is used in
`the discharge system with a lower rated
`pressure capability than that listed on the
`pump data plate, the pressure relief valve
`must be set to relieve at a pressure equal to
`or below the rated capability of the lowest
`rated such component.
`
`400TLS996 Page 4
`
`Page 10 of 52
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`

`

`
`
`Following this visual examination, the hose
`assembly should be hydrostatically tested,
`on test stands having adequate guards to
`protect
`the operator, per
`the hose
`manufacturer's proof test procedure.
`
`Fluid end component inspections should
`be performed more frequently than every
`six months if pressures above 2500 psi
`are used in the discharge system or if
`corrosive, abrasive, flammable, or hot
`(over 110º F) fluids are being pumped.
`
`Proper stuffing box packing selection is
`important for safe pump operation. Contact
`a Gardner Denver service representative for
`assistance in selecting the proper packing
`before beginning operation.
`
`Before starting the pump the first time and
`periodically
`thereafter, check
`the pump,
`suction and discharge system
`fastener
`torques versus the values listed on page 35
`to ensure proper tightness. Over and under
`torquing can damage
`threaded pipes,
`connections and fasteners, which may lead
`to component damage and/or
`failure.
`Replace all components
`found
`to be
`damaged or defective. On pumps equipped
`with stuffing boxes, the gland must be
`engaged by at least three (3) threads to hold
`the discharge pressure of the pump.
`
`
`
` DANGER
`
`
`Do not attempt to service, repair, or
`adjust the plunger packing or other-
`wise work on the pump while the unit
`is operating. Shut off the pump drive
`engine and relieve the fluid pressure
`in the suction and discharge systems
`before any work or investigation is
`performed on the pump or pump
`systems.
`
`
`Block the crankshaft from turning and make
`certain that 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 the entire suction, discharge and
`pump
`lubricating
`systems
`for
`leaks.
`Thoroughly
`investigate any 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
`the used gasket and replace it with a new,
`genuine Gardner Denver gasket before
`reassembling the joint.
`
`Due to the high working pressures contained
`by the fluid end, discharge manifold, and
`discharge
`piping, welding
`on
`these
`components
`is not
`recommended.
`
`If
`welding on the discharge system cannot be
`avoided, only experienced, qualified welders
`should be used. 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
`working pressure, with no observable fluid
`leakage, before the part is reinstalled in the
`pump system.
`
`In summary, high pressure fluid streams can
`possess sufficient energy to cause personal
`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 has
`propelled if the pump system is improperly
`used, or if the fluid is misdirected or allowed
`to escape
`from defective or
`improperly
`maintained equipment.
`
`FLAMMABLE, HOT, COLD OR
`CORROSIVE FLUID PUMPING
`
`
`
` DANGER
`
`
`Extreme caution must be exercised
`by trained and experienced operators
`when
`flammable, hot, cold, or
`corrosive fluids are being pumped to
`avoid personal injury, death and/or
`equipment damage due to explosion,
`fire, extreme cold, or chemical attack.
`
`400TLS996 Page 5
`
`Page 11 of 52
`
`

`

`
`
`Never operate a pump which is pumping
`hydrocarbons or other flammable, hot, cold,
`or corrosive fluids when any part of the
`pump, suction system, or discharge system
`is leaking. Stop the pump immediately if any
`leakage, 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 system, or
`discharge system. Shield the pump, suction
`system, and discharge system to prevent
`any flammable, hot, cold, or corrosive fluid
`leakage from dripping or spraying on any
`components, flame, sparks, hot objects, or
`people. Inspect the plungers, packing,
`gaskets, and seals
`for
`fluid
`leakage
`frequently and replace all worn or leaking
`parts.
`
`Selection of the proper gaskets, seals, and
`stuffing box packing is even more critical
`when flammable, hot, cold or corrosive fluids
`are being pumped
`than when other,
`inherently less dangerous fluids are used.
`Contact
`a Gardner Denver
`service
`representative for assistance in selecting the
`proper gaskets, seals, and packing before
`beginning operation.
`
`the
`into
`Since some packing weepage
`cradle area is inevitable, the drain at the
`bottom of the cradle must be connected to a
`drain line which conducts the fluid leakage
`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.
`
`Before beginning pumping operations or
`starting the pump power source (whether an
`engine or electric motor), check
`the
`atmosphere all around the pumping site for
`the presence of flammable or explosive
`vapors. Do not begin pump operation (and
`stop ongoing operation) if flammable 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 are present
`in the pumping site atmosphere, an engine
`could continue to run on these vapors even
`
`after the engine fuel line is shut-off if an air
`inlet shut-off is not used.
`
`In addition, on pumping units used where
`flammable or explosive vapors could form,
`all electric motors used as power sources
`must be of explosion-proof construction and
`all electrical components and wiring must
`meet the current National Electrical Code for
`explosive atmospheres.
`
`These precautions must be taken to avoid
`possible personal
`injury, death and/or
`equipment damage from explosion, fire, or
`burns.
`
`
`HIGH PRESSURE LIQUID JETTING,
`BLASTING AND CLEANING
`
`
`
` DANGER
`
`
`Extreme caution must be exercised if
`any type of wand, gun, nozzle, or any
`other pressure- and flow-directing
`device
`is attached
`to
`the pump
`discharge system for use in jetting,
`blasting, cleaning, etc. This type of
`equipment must be used by trained,
`experienced operators with
`the
`utmost care. High pressure fluid
`streams can, either by direct contact
`or by propelling loose objects, cause
`serious personal injury or death to
`operators and/or other persons.
`
`
`Pressure- or flow-directing devices often
`receive pressurized flow through flexible
`hoses, which can burst if they are kinked,
`cut, abraded or are otherwise worn,
`damaged, or pressured above their rated
`capacity. Protect the hose and connections
`from damage by people, objects, and
`vehicles. A broken, cut, or otherwise burst
`hose can release pressurized fluid which
`may cause personal injury, death and/or
`equipment damage.
`
`400TLS996 Page 6
`
`Page 12 of 52
`
`

`

`
`
`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 backward thrust of a hand-held device.
`In addition, a safety harness or safety net
`must be used when working in an area
`where the operator could be injured in a fall.
`Stand to the side of any tubing or container
`being sprayed to avoid back spray and
`never operate a hand-held device above
`shoulder level.
`
`Never direct the pressurized fluid stream at
`one’s 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