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0% found this document useful (0 votes)
260 views29 pagesPump 850
BPCL mudpumps
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paonemechCopyright
© © All Rights Reserved
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Available Formats
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ces
CARE AND OPERATION MANUAL
TRIPLEX MUD PUMP
A-850 PT
BHARAT PUMPS & COMPRESSORS LTD.
A Government of India Enterprise
NAINI, ALLAHABAD-211010 PUMP MODEL: A-850PT
BPC S/O
CUSTOMER
ORDER NO.
ait] BHARAT PUMPS & COMPRESSORS LTD.
India E
pc NAINI, “ALLAMABAD—211010 FOREWORD
It is suggested that the PARTS LIST which accompanied the shipment
‘of this machinery be reviewed and maintained as a reference for
detailed repair and replacement. Parts identification in this publi
will be general terminology and wi
part number, size, material, ete.
tion
ot make reference to specific
Before performing any service function, be certain thet the unit
js separated from its power source or the power source it locked-out
to prevent any form of energy from entering the equipment t
would include electrical or mechanical energy into or from the
Prime mover (s), electrical energy to the lubricating pump, charging
Pump, flushing pump, etc, as well as hydraulic energy from the dis
charge or suction lines.
When other than routine servicing is necessary, it can be most effi
‘ently performed IT the unit is removed to an area of adequate space
where an overhead crane or hydraulic lift, hydraulic press, beating
pullers, impact tools, etc. are accessible.
Exercise safety in all performances, do not ignore any cautions, use
only approved methods, matetials and tools. Do not permit eny fune-
tion of questionable safety.
SAFETY IS YOUR BUSINESS AND YOU ARE INVOLVED. INTRODUCTION
This manuel is published 9s 8 guide for the installation, care and
operation, disessembly & reassembly of your unit. The recommenda~
tons made here for the performance of normal servicing are bated
‘on many yeats of experience in the manufacturing, maintenance
‘and servicing of this equipment. However, unusual or extreme
clrcumstences may atise and these must be referred to the manufac
turer. The manufacturer will, upon request and contact, provide
trained, experienced personnel to assist you in the maintenance
and servicing of this machinery.
Improvements in design, engineering, materials, production methods,
ttc, may necessitate changes in this product and result in inconsisten-
cles between the contents of this publication and the physical
equipment. We reserve the right to make these changes without
incurring any obligation for equipment previously ot subsequently
delivered. SINo.
emrausene £
#
ae
Important Features
Breif Description
General Section Of Piston Pump
Specification
Performance Data
Technical Information
Installation
Preparing For Operation
Placing In Operation
Torquing values for Fasteners
Lubrication
Maintenance
Trouble Symptoms
Storage Of Pump
Drawings And Technical Details
Out Line Drawing
Fluid End Assembly
Valve Service
Power End Assembly
Diaphragm Assembly
Connecting Rods
‘Crosshead
Shaft Assembly
Crank Shaft Assembly * Pinion Shaft Assembly
Liner And Piston Assembly
Liner And Piston
Jack Shaft Assembly
Liner Flushing System
Internal Lubrication System
External Lubrication System
Oil Level Assembly
Recommended Spares
List Of Standard And Special Tools
Hydraulic Valve Seat Puller
Hydraulic Pump
Removal Of Liner Centering Sleeve
Removal Of Single Acting Piston
Removal Of Liner Wear Plate
Mud Pressure Gauge
Reset Relieve Valve
Pulstaion Dampener
53
57
62
7
74
75
81
RSEBB
98
106 IMPORTANT FEATURES
HORIZONTAL DESIGN.
WELD FABRICATED STEEL POWER FRAME.
ADJUSTABLE REPLACEABLE CROSS HEAD GUIDES AND
CROSS HEAD SHOES.
INDIVIDUAL FORGED STEEL FLUID CYLINDERS.
API VALVES AND SEATS.
SCREW TYPE, SELF LOCKING VALVE COVERS.
VALVE POTS INDIVIDUALLY ACCESSIBLE
SUPPER DI-HARD LINERS.
METAL TO METAL LINER RETENTION.
SLIP SEAL TYPE PISTONS.
INTEGRAL FULL CIRCLE LINER FLUSHING SYSTEM.
SEPARATE BOLT ON SUCTION & DISCHARGE MANIFOLDS
ROLLER BEARINGS THROUGHOUT : CRANKSHAFT,
CONNECTING RODS AND CROSSHEADS.
PRESSURE CASCADE LUBRICATION.
DOUBLE EXTENDED PINION SHAFT.
SINGLE HELICAL GEARING. BRIEF DESCRIPTION.
Designed for heavy duty service, this pump is @ 9 inch stroke, horizon
tal, single acting triplex pump with a maximum rated horsepower
of 850 at 160 rpm. Weight is 16,000 Ka.
The use of moder high strength steels and latest techniques in
fabrication plus long experience in pump design, menutactrue and
‘essembly have resulted In a product unexcelled in the industry. The
extrome volume-pressure capablities of this pump are developed in
fan all welded steel! power frame. Double row spherical self-aligning
roller bearings support both eranlahaft and pinion shaft. Straight
roller bearings are employed in the connecting rods at crank and
‘crosshead ends. Crossheads are cast ductile iron, operating in tenew=
fable shim adjustable guides.
‘The connecting rads are two-piece design which permits seperate
Installation of connecting rods into pump end in-frame assembly
fof connecting rods to crankshaft.
‘The dual lubrication system is designed to provide constant trouble
free operation. The cascade oiling system will temporarily provide
lubrication even in the event of oll pump failure. An independently
driven oll pump Is recommended and is required when the pump
Is operated under 50 rpm.
‘The three fully Interchangeable and individually replaceable "L"
shaped fluid cylinders afford easy maintenance. For time saving
fend convenience, the piston rods and threaded two-piece construc
tion, which quickly disassemble to facilitate removal of piston without
disturbing the liner.
Valves and valve seats gre removed and replaced thru individual
Valve covers. This pump incorporates all features contributing to
low cost, trouble-free maintenance.
‘The basic pump is comprised of a power-end and « fluid-end mounted
fon short steel skids. The power-end contains the shaft assemblies,
‘connecting rods, dlaphragms, etc. The fluid-end contains the fluid
‘chambers, suction manifold, discharge manifold, valves, seats, pistons,
liners, ete.
‘The lubricetion system with its provisions for filtration and cooling;
the liner flushing system with Its circulation unit, the features of
{8 piston rod.back-up tool, the mechenical turning device, etc. are
all added to the basic unit to compose the standard unit as outlined
Jn this publication.
‘The laterality of the unit i, es reflected here, determined by standing
fat the power-end end looking toward the fluid-end-reterence is
made to the left hend side and the right hand side. The fluid chambers
‘also designeted from this same position-the No. 1 fluid chamber
Js on the left hand side, the No. 2 Chamber is in the center and the
‘No. 3 Chamber is on the right hand side. 4DSD-0101
a { \ ta, se J Neg
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US
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a
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0 Pump Specifications:
Pump size (Max. Piston diaxstroke)
Standard Platon sizes ..ee.eeee seco
Rated Input Brake Horse Power at 160 rpm .
Gear Ration (Built-in). -+6.eseeeeeeeeeeee
Maximum Working pressure Discharge
sees pal
Suction ees ees sete eee eee pal
Suction Connection + (Flange ANSK 150 Ibs WNRF) ..eeeseseeeeeeeeeeees Inches
«inches
Discharge Connection (Flange API-5000 Ibs, RT}, both sides)... +++ ++
+ (Flange API-5000 Ibs, R.T-} Center only) sss +++
inches
Pinion Shaft Extension + diameter . .
+ Length ..
Keyway (WidthxDepth) . .
Crank Case 26+
Oi Capacity
Weight (Pump with std. equipment and Skid) -
Over all Size + Length (Pump on Skid) oeseeeeeeee ees
+ Width (over pinion sheft) ...eesseseeeeees
2 Hight.
Maxs
12,6, 61/2
7 and 71/2
850
4aeet
203
3a.
50x19
322 10
RFORMANCE DATA:
ton a DISPLACEMENT
sim | Preenne | Per rev Gates por mine at pap Speed (ron)
Inches pal o | 100 10 | 10 160
5 3565 230 138 1 | (BO 25 3a 367
sa 2906 20 167 m 20 vs | 309 oy
6 2076 330 198 264 330 vor | aes 329
oe 2110 3.88 233 310 388 465 343. eat
7 1019 450 270 360 450 so | 630 70
ae 1508 sis | 310 as 316 oo | om 026
BRAKE Input Horse Power 318 25 ot or | ms 850
Input Pinion Shaft rpm 269 358 aa se | ear m
Based on 90% mechanical and 100% volumetric efficiency
CONVERSION FORMULAE,
1 cubic Metre per day (m?/d) = 6.2898 Barrels per day (bpd)
1 Gallon per minute (gp) = 3.78533 Litres per minute = 231 Culn/min
1 Kilowatt (KW) = 1.38102 Horee Power
1 Kilogram (Welght) (Mess) = 2.2086 Pounds
11 Kg/Cm? = 98.067 Kllopascals (kpa) = 14.2234 pal
‘9pm x pal
Broke Horsepower =
1718 x 0.90 (Mech. EI.
Bartels Pet Day = gpm x 34.3
Barrels Per Day = Gal. Per Rev. x rpm x 34.5
‘Inch = 25.8 me (mllimetres) (exactly)
‘1 euln. (cuble Inch) = 0.016 387 (tres) (exactly)
‘Area of Plunger x(Length of Stroke xNumber of Plungers)
231
Gal. Per Rev. =
Gal Per Min. = Gal Per Rev. x rpm 1
TECHNICAL INFORMATION
‘The following details are presented to permit identification of the valve service pistons and piston rods
under Industry standards, as @ guide to the proper setting or clearance of ratating and reciprocating
parts and includes data pertinent to the unit ot its function.
ROTATING AND RECIPROCATING PARTS
Pinion Shaft Bearings:
Type.
Spherical
: ble
se eteeeeeeeeeeeneeeeeeeseessh25 to 150 mm End Play
Clearance Spondosnendd
Lateral Clearance of Shaft «
Crank shaft Bearings:
+++ Spherical
+ Non-adjustable
1.25 to 1.50 mm End Play
Clearance... s..4 0+ soga
Lateral Clearance of, Shafts... ssseeeeeeeee
Se oe cere
+++ Spherical
Non-adjustable
1:25 to 38 mm End Play
Straight Roller
Non-adjustabie
seeeseee Straight Roller
+++ 0.000 to Minus .075 me
Non-adjustable
Clearance - Crosshead Pin in Crosshead ..
Clearance - Bearing or Bushing to Crosshead Pin. «
Croashead:
Clearance - Crosshead to Crosshead Guide.
VALVE SERVICE
Size... ++
10 to -60 mm
teeter eee APINOS 7
Accessibility. eecbaonoanen Baoceoenrdscooen Individual
Cm ee -Setew Type
PISTONS
Dorion eee ee ee Arca
Func
Material *,
PISTON RODS
Designation
Func
Materi
CYLINDER LINERS
Material . :
MISCELLANEOUS
Tools:
Valve Seat Puller ..sssseeeeeeeeeeeseeereeseseseeseeseeeaessenesens eHydtaullon®
Tool for Piston Installation & Removal... +++ssssseeeeeeeeeseeseeees Furnished With Pump
Tool for Piston Rod Nuts «+++ ++ si eteeeeeeeeeeecseeees Spline Wrench or Socket
Tool for Body Fitted Bolts on Power Frame... Wrench for 7Omm Nut
Mechanics Tools (Sockets, Box End Wrenches, etc.)- Max. 45mm Nuts
testes sees eren sess s Single Acting
= Regular or Oil Resistant
+ APL SAG
Single Acting
++ Super DI-HARD
‘Consult manufacturer for recommendation.
+ *May be purchased separately from pump manufacturer. 12
INSTALLATION
The installation of your pump, if carefully planned and 2. The skid or foundation must be of sufficient strength
adequately performed, is the first most important step in to prevent flexing of the equipment.
Providing for tong, trouble free service from the PUMP 5 THe skid or foundation must be of sufficient size and
125 well as the associated equipment. Review the specifica-
i ted oc e design to maintain the equipment free of strain,
tons and performance data on the preceding pages and
be sure that the flow system is of sufficient design to insure 4 The equipment, must be adequately secured to the
safety at elevated pressures and that it provides a safe skid or the foundation. Hight strength bolts ot capscrews
pressure relief In the event of flow interruption as well with locking devices are generally employed.
‘as immediate shut-down should line failure occur. Safety
5. Consideration should be given to the location of the
guards for all reciprocating and rotating elements should
equipment with its proximity to the associated equip
be mandatory at the time of installation. Hand rails, supports,
tie-down, shields, deck plating, etc., must be considered
ment, fluid supply, fuel supply, environmental contami
in your progtam. Make it a safe instalation. ea!
‘The following considered basic installation requirementst 6. Avoid environmental contamination by providing for
Aon the proper disposition of drainage from the crankcase,
‘gear case, chain case, sludge sump and any other
1. The skid of foundation must be level Angular installation Iubrioaton reservelrs os well as trom the. thahing
media resetvoir, the flushing media sump, the pump
cradle, the suction line and the discharge line.
land operation may be detrimental to the lubrication
of the equipment and may impose high stresses causing
equipment f
PRIME MOVER GEAR OR PUNP
(orien) (riven)
it
With the pump and prime mover on the skid oF foundation, use a straight-edge or chalk line to determine the relative
position of these two components. When close elignment is achieved, install the belts or chain and adjust for proper tension
then reposition the prime mover to obtain full surface contact between the straight-edge ot chalk line and the sheaves ot
sprockets at points (A), (B), (C) and (0). Retain this alignment and readjust the belts ot chain far tension. Secure the compo-
rents to their mounting. ALIGNMENT
1. It is most important thet the pump be accurately aligned
with the prime mover. Fig on page 12 will guide you in
the alignment if V-belt or chain drives are provided.
UF flexible couplings are used, follow the alignment
recommended by the coupling manufacturer.
When alignment is achieved it should be reinforced
by shear blocks or dowel pins.
PUMP SUCTION
Single acting pumps require @ flooded or charged
suction for proper performance. A net positive suction
pressure, as provided by en adequate centrifugal
charging pump, will ai inthe filling ofthe fluid cylinders
oper
jing pump should have a capacity
‘and reduce the era
fon caused by cavitation
Generally, the char
equal to 11/2 times that of the triplex pump
2. The suction flow should'be streamlined through gradu
turns with friction not greater than those caused
by 45 deg, long radius elbows. Do not install any bend
directly adjacent to the pump intake.
3. The suction line must not be smaller then the pump
suction preferable the line should be at least one
pipe size larger. The line should be as short 9s possible
‘nd the fluid velocity should not exceed 3 feet/second.
In the pumping of solids it may be necessary to exceed
this velocity to prevent the product {rom settling out
of the cartier fluld. In this service, maintain the lowest
possible velocity ond the lowest possible pump speed
to provide for maximum pump performance.
‘A suction stabilizer is: tecommended-inst
led a8 close
fs possible to the pump suction,
Install a full-opening gate valve or butterfly valve
at the supply tank to permit the suction line to be
closed and drained when necessary. Do not we a
with any flow restriction.
6. Install a. drain valve at the lowest point in the suction
system.
7. Install @ pressure gauge at the pump suet
8. Install low suction pressure alarm system.
4. Wwitall a theemometer well at the pump suction.
13,
10.
n.
nm
Do not introduce meters or any
ricting device
10 the suction tine.
is not recommended,
but if it should be necessary
to manifold @ number of pumps to common suction,
the suction pipe from the supply tank and the manifold
must ha
8 cross-sectional area equal to or greater
than the total cross-sectional areas of all the pump
suctions connected to the manifold.
Support the suction line st the pump and at the supply
tank to remove any Imposed stresses or strains. Additio-
‘nal supports, dependent upon the length and configura
tion of the suction line, may be necessaty to reduce
fatigue and vibration.
0. PUMP DISCHARGE
.
‘The cischarge line must not be smaller than the discharge
fat the pump.
‘The discharge from the pump should be stteam-lined
through gradual turns with friction not greater then
those caused by 45 deg, long radius elbows. Do not
install any bend directly adjacent to the pump discharge.
Install a discharge pulseion dampener as close to the
ump 2s possible.
Any valves in the discharge line must be full-apeningtype.
Install @ pressure reliet valve ahead of any valve in
the discharge line. It must be set at © pressure not
‘greater than 25% above the rated working pressure
fof the pistons or plungers being used. The discharge
from the relief valve should be directed through @
securely positioned tine back to the supply tank (not
to the pump suction).
Install a by-f
without load. This permits servicing of the equipment
‘and circulation of lubrication prior to loading the pump,
ss line to petmit the unit to be operated
Install @ pressure gauge at the pump discharge.
Install a high-low pressure alarm system. This may
be supplemented with time delay shut-down, 14
SHEAR BLOCKS
‘AL GENERAL
Machinery items are generally mounted on machined pads, "H!" beams or bed-plates and retained with capscrews ot
hhold-down bolts. The flexing of loaded machinery will cause these capscrews or hold-down bolts to become loose
land ineffective for the retention of alignment of the machine with its associated equipment. When the equipment
Is being made ready for operations it should be carefully aligned, secured with the capscrews or hold-down bolts
then its position reinforced with dowel pins or shear blacks (this is applicable to items which need not be moved, [tu
pumps, rotary tables, etc, however, engines or other prime movers which must be moved for belt ot chain drive
‘adjustments should be equipped with slide rails and in these installations the slide rails should be "doweled" or "blocked".
Also, the shear blocks serve @ dual purpose, they ate guides, fot the re-installation of « machinery it
been removed from its base for servicing or any other reason.
sm once It has
Bi. INSTALLATION 4 Weld side "C" again, start at the outside comer
‘and weld continously toward the retained object.
[As indicted above, be certain that the equipment
is in alignment and that the capscrews or hold- a epee lore atta be etalleg sonoma, (2)
down bolts ate properly tightened. each other this placement with this outlined
welding procedure will then place the retained
Hold the shear block firmly in place and tack-weld ‘object in compression.
it at point "ar,
6 Recheck the alignment of the equipment. If
It has been distorted,
Continue to hold the shear block in place end
weld side "6" start at the outside cornet and
weld continously to toward the retained object. seme instructions to install new shear blocks.
(1) Object To Be Held
(2) Shear Blocks Certain preperations a1
PREPARING FOR OPERATION
necessary befo
the pump can
bbe placed in operation. It Is suggested that all check points
in the MAINTENANCE section of this publication be observed
fend executed prior to releasing the pump for service. The
following is a guide for general preparation.
A
GENERAL
1. inspect the unit for any damage or defects.
2. Check sheaves/sprockets/couplings for proper
alignment.
3. Check belts or chain for proper tension.
4 Check fuel, water, suction, discharge and drainage
piping.
5. Check safety guards for maximum protection.
6 Check satety devices for malfuntion.
FLUD END
1. The fluid end is normally shipped complete with
the valves and seats installed The liners and
pistons will, if delayed start-up is. indicated,
be shipped unassembled.
2 Remove valve covers-inspect the valve service
and the interior of the fluid end for defects
ot foreign materjals,
POWER END
1. Check rotation. The pump is designed for clockwise
rotation of the crankshaft when viewed from
the tight hand side. Right or left hand side is
determined by standing at the power end and
looking towerd the fluid end, REVERSE ROTATION
MAY BE DETRIMENTAL TO THE UNIT (check
with manufacturer if reverse rotation is necessary).
2 Remove inspection doots and covers-check
the interior of the pump for ditt, rust, water
‘and foreign objects, particularly if the pump
‘has been in storage. If necessary clean and
‘wash out the power end with non-toxic, inort-
explosive solvent.
Replace the inspection doors and cavers.
b. Check and be sure the drains are closed.
3. Fill the crankcase with correct amount of the
Proper lubricant as indicated in the LUBRICATION
section of this manual.
The filling may be accomplished by removino
the breather on top of the crank-case and
Introducing the hubricant at this point.
'. Replace the breather.
4 Fill the flushing system with the correct quantity
‘of the proper fluid as indicated in the LUBRI-
CATION section of this manual.
‘& The filling is accomplished by introducing
the fluid to the cradle section of the pump
where it will gravitate to the flushing system
sump. 16
PLACING IN OPERATION’
If the unit has been prepared for operation es outlined
in the foregoing, procede to place the unit in service. The
{following is a guide for initial startup.
HH the pump is equipped with an externally driven
lubricating oil system, energize the system five
minutes in advance of start-up.
I the pump is equipped with an integral lubricating
cll system or has @ combination splash /cascade
ciling system, remove the inspection doors and
‘covers from the power end, introduce @ copious
quantity of the lubricating media into the bearing
reservoirs, crosshead ways, crenk pin bearing
troughs, ete. Replace the doors and covers.
Check the temperature of the lubricant in the
crankcase, This must be within the limits specified
Jn the LUBRICANT TABLE which appears subse-
‘quently’ this publication.
It the lubricant is below the minimum specified
egree it can possibie be increased in temperature
by circulating it through the lubrication system.
this action does not bring the temperature
&p to the minimum level introduce hot water
into the heat exchanger or use emersion type
heaters.
11 the lubricant is above the maximum specified
degree it must be cooled. The heat exchanger
with cool (cold) water flowing through it is
for this purpose. Circulate the lubricant through
the heat exchenger until it is within the operating
range.
If the pump Is equipped with @ flushing system,
‘energize the flushing system.
00 NOT PLACE THE PUMP IN OPERATION OR
MAINTAIN IT IN OPERATION WHEN THE TEMPE
RATURE OF THE LUBRICANT 15 ABOVE OR
BELOW: THE LIMITS STATED IN THE LUBRICANT
TABLE APPEARING IN THIS PUBLICATION.
5
n
10,
Rotate the pump one full revolution by hand
to be certain all moving parts are tree and can
‘move unrestricted.
Open by-pass valve.
Open valve at suction tank.
Apply power slowly, check direction of rotation
fend control at low rpm to prime the pump fluid
chambers.
Open the valve in the discharge line, increase
power, close by-pass valve and observe the
following.
Check lubricant pump to be certain of flow
In the lubrication system.
Check flushing system- for proper distribution,
Check for fluid leaks at "tattle-tale" holes in
‘uid cylinders.
Check for fluid leaks at "atti
valves pots.
Check for lubricant Jeaks at diaphragm.
Check suction pressure.
Check discharge pressure.
Check lubricant temperature.
Check suction stabil
level.
Check discharge pulsation dampener for charge
pressure.
tale" holes in
fer for proper operational
Check for lubricant leaks in extemal piping.
Check for fluid leaks in suction and discharge
piping.
Check all external bolting for proper torquing.
Hf operations are below 50 rpm consult manufac-
turer for lubrication instructions.*
‘*Not applicable to pumps with separately driven 7
TORQUING VALUES
TORQUING VALUES FOR FASTENERS
Sizes Required Torquing values
The proper torquing of all bolts, studs and capscrews is DIAMETER | Alloy steel studs | Cap Screws & Botte
IMPORTANT. Improper torquing will cause breakage by | —J—— TAGs ars
fatigue or yield and serious damage of hazards can ensue.
va | Me 09 or
5/6 | Me 18 1
A. GENERAL 3/a | M10 33 23
Original equipment consists of fasteners produced [746 | wiz oa a
from alloy steel or heat treated alloy steel (low carbon | yo | sata 17 62
steel or materials of tess yield strength are not used | sig | mie 153 faa
3a | M20 2a 220)
1B. INSTALLATION OR ADJUSTMENT vs | M22 440 326
1. Clean and lubricate threads with » good quality fe eraze) eu ae
anti-seize compound. ey Ss ae
2 Be cettsin tightening progresses uniformly to
prevent misalignment or damage to the components. GED i) oa
3. The values shown are to be observed in the M36 tro wi
final tightening of the fasteners.
rave y |
138 Kg. m..
| 69 Kam.
12 Kom,
ah i 12 Kg. m.
12 Kg mu
. 27 Kg, me 876 Kg: me
: 69 Kam \276 Kam. 19
fA film of lubricant must
be provided with sufficient strength to withstand localized contact pressures at all points of moving,
contact to prevent accelerated wear of the moving patts. The basic principle in the selection of lubricants,
Is to choose the least viscous that will retain a fllm coverage and withstand the loading of the moving
parts.
When filling the ctankease, remove the inspection door from the crankcase cover and introduce at least
20% of the lubricant into the crankcase cover oil trough and scraper trough adjacent to the main gear.
Oil may be added to the crankcase by removing the alt breather and pouring the oil through that opening.
In the initial filing of the crankcase with lubricating oll and when the oil is being changed, it is suggested
that the crankcase cover be removed and the interior of the pump be cleaned and inspected. At the
seme time, drain ond clean the sludge trap, clean the oil strainer, clean the air breather, and (when
changing oil) change the filter cartridge and clean the magnetic filter. f the oil was contaminated
with foreign material, ke. sand, dirt, metal cuttings or chips, paint, light hydrocarbons, pumped product,
etc fill the crankcase with a non-toxic, non-explosive solvent, install @ new filter cartridge and use
‘an external drive for the lubricating oil pump to circulate the solvent for a minimum of five minutes.
It the pump is equipped with an electric motor dtiven oil pump, use this to circulate the solvent, if the
cil pump is driven from the jackshaft, remove the v-belt and use an electric or pneumatic drill (or similar
Gevice) to activate the oil pump to cicculate the solvent without rotating the shaft assemblies or moving
the reciprocating parts.
After circulating the solvent, remove the ctankcase cover, drain the solvent, inspect and clean the
intetior of the pump, change the filter cattridge, drain and clean the sludge trap, clean the oil strainer
‘and clean the magnetic filter. Replace the crankcase cover and fill the crankcase with 20-W or 30-W
‘mineral oll or non-detergent motor ofl.
Used to circulate the
fe minutes. Continue
Use the electric motor driven oll pump or externally driven pump, the same
solvent and circulate the mineral oil or non-detergent motor oil for @ minimum of
i skéwly, without any loading, rotate the crankshaft approximately 10 revolutions,
of the
to circulate this
Drain this oll from the pump and follow the same procedures as that outlined for the remov
Use the quantity of specified lubricant as per Table given on next page to fillthe crankcase. If the meche-
nical drive was disconnected {rom the oll pump be certein that it Is reinstalled and adjusted before
retutning the pump to service. Check the oll level at the oil level dip-stick, the oll level should be between
the high and low marks on the stick (do not check the level when the pump is in operation). When initially
filled, the level may be above the high mati on the stick ; however, after a few minutes of unloaded
‘operations the filling of the sludge trap and other reservoirs, the oil level should be between the high
‘and low marks on the dipstick. 20
LUBRICANT TABLE
CRANKCASE LUBRICANT
CAPACITY TYPE LUBRICANT SAE Lock
oF TEMPERATURE viscosity | cauiva'eNT
uTREs LUBRICANT (OPERATING NUMBER
CONDITION)
SERVOGEAR
EXTREME HP 140
322 PRESSURE 32°c to 82°C 140 oR
HEAVY DUTY
INDUSTRIAL . 'SERVOMESH
La SP. 460
LUBRICANT.
OWL CHANGE & CLEANING.
After 600 to 800 operating hours the oil is to be changed for the first time.
Upon stopping the pump oil drainage is to be effected immediately while the
oll is still warm. Subsequent oil changes are to be made within 3000 to 5000
operating hours. During the oll change the pump is to be cleaned throughly
and flushed with wash oll. While doing this, absolute cleanliness is essential
50 a8 to ensure that-no foreign matter enters the interior of the gear. When
assembling, itis necessary to see that ell joints in the oll piping system are
tight.
FLUSHING LUBRICANT
service | CAPACITY TYPE TEMPERATURE | SAE NO. LOL
PERIOD uiTeRs EQUIVALENT
‘SERVO-
50% MOTOR SUPER 30
EVERY 6 8 ‘Ol PLUS, ALL 30 OR SERVO-
MONTHS 50% DIESEL No. 2 SUPER 40
FUEL 21
GENERAL
1. Use only the quantity and grades of lubricant listed on
2 Maintain the lubricant free of all contamin-sction (fluids and solids).
3. Change lubricant at the end of the setvice periods listed
4. If contaminated, change tubs
5. Maintain continuous lubricant flow under all operating conditions.
Maintain the temperature of the lubricant within the ranges listed above.
7. Change the filter cartridge when the lubticant is changed,
8. Change the filter cartridge when the pressure scross filter incteases 1 Kg/Cm.2
9. Clean the magnetic filter every 8~ hours duting first week of dperations.
10, Clean the magnetic filter once each month (after first week of operations).
11, Clean lubricant strainers once each month (Minimum).
12, Drain sludge sump when dreining crankcase lubricant. Er]
MAINTENANCE,
GENERAL
The requirement for @ maintenance program can-
not be over emphasized. This equipment represents
‘considerable investment and its function is necessary
te your operations. Neglect is costly and will result
in premature failures, early retirement of worn equip-
ment and the junking of unusable machinery.
‘The installation of a maintenance program with positive
execution will reward your operations economicelly
byt
2. Reduce quantity of required repair and replacement
parts.
3. Provide for longer periods of service-free operat
Extend the life of your equipment.
PROVISIONS FOR MAINTENANCE
It is strongly recommended that all pumping operations
bbe supported with stand-by capacity and by 8 spare
parts inventory. The percentage of stand-by capacity
needed to sustain operations is determined by the
operator and the quantity of spare parts in his inventory
is usually dictated by use patterns. Spare parts should
be maintained in inventory to be immediately available
at the point of operations.
© SUGGESTED MINIMUM PROGRAMME
1, The following represents @ suggested MINIMUM
equirement for maintenance. It is designed for
perioc
Inspection and adjustment, it does not
preclude the necessity of immediate attention
to items or elements which become maladjusted
fot worn not is it intended to temave the "common=
sense" factor which Is so necessary in the operation
fof any machanical equipment.
2 As indicated above, this is only @ guide other
maintenance may be desirable and required
to satisty your satety programme, to comply
with established policies, ete. 23
MAINTENANCE
This sisting of cbservations mggested tobe considered when performing maintenance on standard pump Each operating company
‘should prepare their own specific forms for this purpose and insist that an established program be followed and recorded.
Daly
EK OL TEMPERATURE
1 | etx OSG POLATION OREPOER FoR PROAR PRESSE
WEEKLY
‘GOK TOUNORTION WAY OR FOLD-DOWN BOLTS
[GHEE DSOARGE FUME BOLTRE
MONTHLY,
1 | ere tne pron wean
(GEO VALS SATS WO SPARE
IX MONTHS
Gecx Crossiend GORE
‘OHEOK CROSGAEAO PRN CLEARANCE
(GEO CRANR BEARNG CLEARANCE
‘GEOC GINS WO /oR GAN MO SPRODRETS TOR WEAR
[OHEEK PUMP SAVE, PRODTT Of COUPH
"GUE OF (ae Cre Fier Cann)
‘Gaver Ubi MEO
The act of observing and recording a not enough —provide the neceasry tm
{functioning safely and property.
material ana physical effort to keep your equipment 24
TROUBLE SYMPTOMS
It is not possible to diagnose, without a very careful exar
‘operation. The more common symptoms
ation, the cause of ll difficulties which may arise in any pumping
@ listed below. If the remedy outlined here does not alleviate the difficulty,
please refer the matter to the manufacturer's techinicel services department.
OBSERVATION PROBABLE SOURCE [ADJUSTMENT
Teplace Valve Anonbly
fen Ps a
[foo ataras
lLow Discharge Pressure| Improper Filling ‘increase Charging Pump Speed
Decrease Pump speed
Prime Fluid Chambers
Fluid Slippage } + Replace Piston Liner
Erroom Gav Rendng-—{ Reva or Rolece Cape
Charging Pump Capacity Increase Charging Pump Speed
[aaa Ht 1
Retarded Fluid Flow Remove Restrictions from Suction Line
Erroneous Gauge Reading FH. Recalibrate or Replace Gauge
‘Air Entering Suction Line Repair Suction Line
}[air Enterina Charging Pump Tighten or Replace Shaft Packing or Seal
‘Ait Entering Suction Ste
‘Repair and Re-balance
‘Allow More Settling Time
Fluid Knock or Hammer}
Air /Gas in Pumped Fluid
Reduce Pump Speed
Adjust Suction Stabilizer
Sonor Se OBSERVATION
25
ROUBLE SYMPTOMS
PROBABLE SOURCE
[—{ Discharge Pulsation Dampener KH Repair and Recharge or Replace
ADJUSTMENT
Unsupported Discharge Line
Provide Supports of Hangers
Discharge Line Vibration]
Sone a Law See Preset —
‘Same as Low Discharge Pressure
J
‘Same as Low Sucti
Prowse | —[ ew tow Scion Prom
Some as Fluid Knock or Hamme }—_ Seme as Fluid Knock ot Hammer
KH
Loose Liner Adapter Nut
Tighten Liner Adapter Nut
Loose Valve Cover
Tighten Valve Cover
Valve Not Seating
‘Short Valve Life
1 {Worn or Damaged Gasket | Reolace Gasket
Replace Valve Cover
Lf Damaged Gaskat Surtace HH [Reslace tiner Wear Pia
‘Abrasives in Fluid
Large: Particles in Fluid
|
Repair Fluid End
(Check Desander Desilter
Sereen Pumped Product
Broken Valve Spring-Replace
‘Pump Not Filling
Pulsation Dampener Maltunction
c ‘Abrasives in Fluid
eS}
\_[ wom vaive/ seat Replece
c Treat Pumped Fluid
‘Corrosion H
Worn Valve Guide-Replace
[Repair or Replace
Use Different Materials for Valves/Seate
Check Desander /Desilter
‘Short
iner Lite
|
Repair Flushing System
Use 50% Oil & 50% Diese! Fuel to Flush
Use Super Di-Hard Liners
Use Regular or Oil Resistant as Required TROUBLE SYMPTOMS
OBSERVATION
PROBABLE SOURCE
Worn or Demaged Extension Rod
ADJUSTMENT
Replace Extension Rod
{feared tron Roo
Clean and Polish or Replace Extension Rod
llowscar aap He Cantern Ring
Toit sate misplaced
Worn Wiper Rings
H Wiper Rings Improperly Sealing
[Replace Wiper Rings
Check Installation Directions
Clean and Polish Diaphragm Bore
]—[resnce tate Brg
| [eck tatlaton recto
[Reservoir in Diaphragm Housing
Install Orain Hole at Bottom
Clean Drain Hole
Worn Sealing Lip
[mes Sealing Lip
10.D. Not Seated lean and Polish Bore of Oil Seat Housing
Foreign Material at Seal Point
p[cecen and Poli shat
LY Clean and Polish or Replace Shaft Sleeve
| [isms Cran
|_[sean or Rape Ar Brea
Low oil Level
{creck and Add oi 1 Necessry
Contaminated Lubr
Low Oil Pressure
High Oil Temperature
sant
Relief Valve Maladjusted
Leakage in Piping System Repair All Leaks
See observation "High Oil Temperature
Change Olt
‘Check and Reset
Oil Pump Worn
a Se
[Clogged Suction Screen
Clean Screen and Change Oil
Erroneous Gauge Reading
]—[Frecatiorate or Replace Gauge OBSERVATION
27
TROUBLE SYMPTOMS,
PROBABLE SOURCE ADIUSTMENT
{iw 01 Temperate
Connie 8 } [ime os
in’ Temperature Range
High Oil Pressure
_ Hietet ave manana } [rece and fet
High Oil Temperature
Olt Filter Clogged }-{cranse Fitter Conteiage
Restrictions in Passageways
Erroneous Gauge Reading Recalibrate or Replace Gauge
Clean Tubes and Shell
Regulate Coolant Rate
[improper Bearing Aciustment Check and Adjust Clearances
Incorrect Pump Rotation ‘Check Installation Directions
l
‘Loose Estension Rod
irene ee
ttonse Bearing Housings /Covers
(Check and Tighten
‘Worn Crosshead Pin
‘Worn Crosthead Pin Bushing /Beating
Worn Main or intermediate B
ring 28
STORAGE OF PUMPS
Al machinery units require protection from corrosion erosion, natural attrition which causes deterioration