HHF-1000 Mud Pump Manual

HHF-1000 DRILLING PUMP
November, 2008
Table of Contents
Foreword...................................................................................................................................................1
1 Safety warnings ..................................................................................................................................2
2 General................................................................................................................................................2
3 Technical Specifications and Parameters.........................................................................................3
3.1 Technical specifications ...............................................................................................................................3
3.2 Performance parameters ............................................................................................................................5
3.3 Overall dimensions.......................................................................................................................................6
4 Use of new pump ................................................................................................................................7

4.1 Installation of new pump..............................................................................................................................7
4.2 Requirement to suction system...................................................................................................................11
4.3 Preparation of power end ...........................................................................................................................11
4.4 Spray system ..............................................................................................................................................13
4.5 Checkup in fluid end ..................................................................................................................................15
5 Lubrication .......................................................................................................................................19
5.1 Minimum operating speed..........................................................................................................................19
5.2 Flow-controlled splash lubrication system.................................................................................................19
5.3 Pressure lubrication system ........................................................................................................................20
5.4 Maintenance of lubrication system.............................................................................................................24
6 Maintenance and Assembling of Main Components.....................................................................25

6.1 Power end...................................................................................................................................................25
6.2 Rolling bearing...........................................................................................................................................27
6.3 Pinion shaft assembly.................................................................................................................................28
6.4 Crankshaft assembly ..................................................................................................................................29
6.5 Installing crankshaft assembly in frame .....................................................................................................31
6.6 Installation of crosshead guide ...................................................................................................................33
6.7 Installation of crosshead.............................................................................................................................33
6.8 Check crosshead alignment........................................................................................................................35
6.9 Maintenance of fluid end............................................................................................................................36
6.10 Welding and repair ...................................................................................................................................41
6.11 Replacing air bladder of dampener...........................................................................................................43
7 Information in Maintenance Work.................................................................................................44

7.1 Daily maintenance work.............................................................................................................................44
7.2 Weekly maintenance work .........................................................................................................................44
7.3 Monthly maintenance work........................................................................................................................45
7.4 Yearly maintenance ....................................................................................................................................45
7.5 Other precautions in maintenance ..............................................................................................................46
8 Possible Failures and Troubleshooting ...........................................................................................46

8.1 Fluid end ....................................................................................................................................................46
8.2 Power end...................................................................................................................................................47
9 Attentions in Preservation ...............................................................................................................47

10 Attentions in ordering....................................................................................................................47
11 Special tools list delivered with HHF-1000 drilling pump ..........................................................48
12 Spare parts list delivered with HHF-1000 drilling pump ...........................................................49
13 Recommended spare parts list (HHF-1000 drilling pump) ........................................................50
OPERATION MANUAL OF HHF-1000 DRILLING PUMP
Foreword
HHF-1000 drilling pump is one of the most important equipments for drilling rig. The parts and
components of this drilling pump are designed and manufactured according to API 7K and related
stands. It can satisfy the drilling operation requirements of drilling rig.
For the purpose of making user effectively operate and maintain the drilling pump, we have
compiled this “User’s Manual for HHF-1000 Drilling Pump”. This manual generally describes in detail
the performance parameters, configuration and function, installation and adjustment, operation and
maintenance, frequent failure and troubleshooting, expendables replacement and other precautions etc.
we do our best to ensure the listed data exact, the operating method simple and practical, convenient to
drilling site operator and service personnel.
At the rear portion, we provided the list of spare parts recommended for reference while users do
replacement parts ordering, if the requested parts exceed the range listed, consult the parts list and
drawings attached in manual.
1
1 Safety warnings
1.1 The personnel who are occupied in installation, operation and maintenance of drilling pumps should
be trained and qualified, and carry out the work with qualification certificate.
1.2 The main personnel who are engaged in installation, operation and maintenance of drilling pumps
should be experienced in corresponding installation, operation and maintenance.
1.3 There must be a chief principal for the installation, operation and maintenance and persons in charge
of each work, and detailed and reliable safety measures should be taken.
1.4 All the persons on duty must put on safety wares according to the related regulations. And the
person who works high above the ground should wear safety belt well.
1.5 All the equipments should be used strictly in accordance with their operating rules and related safety
regulations.
2 General
HHF-1000 drilling pump is a kind of horizontal, triplex, single acting piston pump. It feeds and
circulates high-pressure drilling fluid, which flushes the wellbore bottom and crushes rocks, cools and
lubricates drill- bits and carries the cuttings (rock chips) to the surface.
The drilling pump mainly consists of two portion, power end and fluid end (see Fig. 1). The power
end includes the assemblies of frame, pinion shaft，crankshaft，crossheads etc. The fluid end includes the
assembly of cylinder block (fluid end)，valves, liner, piston, suction and discharge manifolds and so on.
The parts and components of this pump are designed and manufactured according to API 7K. All
wearing parts at the fluid end such as cylinder liner, piston and valve assembly etc are universal and
interchangeable and can be replaced with the same type parts and components in conformity with the
above-said API 7K. To avoid ‘air lock’ and reduce outlet pressure fluctuation，a suction air damper and
discharge air damper are respectively installed at the suction manifold and one side of discharge
manifold of pump. At the other side of manifold, a shear pin relief valve is installed to guarantee that the
pump pressure will not excess the rated working pressure. Each pump is equipped with a charging pump
to ensure good suction performances for the pump while operating at high strokes.
A combination of splash lubrication and forced lubrication is adopted to lubricate all gears,
bearings and crossheads at the power end. The cylinder liners and pistons in the fluid end are lubricated,
flushed and cooled by cooling fluid supplied from a spray pump.
For conveniences of daily maintenance, a set of special tools will be delivered along with the
drilling pump package.
As long as the maintenance work is implemented regularly, the HHF-1000 drilling pump will be a
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good dependable fellow to every drilling operator; will bring you excellent economic benefit.
3 Technical Specifications and Parameters
3.1 Technical specifications

For the technical specifications of HHF-1000 drilling pump, see tableⅠas follows.
TableⅠ Technical specifications for pump HHF—1000
No. Model HHF-1000

Horizontal, triplex-cylinder, single acting piston
1 Type
pump
2 Rated input power 1000hp（746kW）
3 Rated stroke number 140SPM
4 Length of stroke 10″（254mm）
5 Gear type Herringbone tooth
6 Gear ratio 4.207:1
7 Connection size of suction port 12″ flange（about 305mm）
8 Connection size of discharge port 5 1/8″flange 5000psi API（130mm flange 35MPa）

Dia. & outward elongation of
9 7 3/4″×131/4″（196.85×337）
pinion shaft
10 Connection size of key 2″×2″（50.8×50.8）
11 Size of valve pot API 6#
160″×124 5/8″×71 9/16″

12 Overall dimension（L×W×H）
（4063×3167×1818mm）
13 Skid length×width 160″×70 1/2″（4063×1790）
14 Weight of main body 18910kg
3
1 2 3 4 5
6 7 8 9 10 11 12 13
1.frame assy. 2.crankshaft assy. 3.pinion assy.

4.crosshead assy. 5.fluid end assy. 6.discharge filter screen assy.
7.cylinder assy. 8.discharge pipeline 9.suction pipeline
10.elbow assy. 11.safety valve 12.air damper
13.anti-shock pressure gauge
Fig. 1
4
3.2 Performance parameters

The performance parameters of HHF-1000 drilling pump are shown in the following table II.
Table II Performance parameters for pump HHF-1000
Cylinder liner dia. and rated pressure
6-3/4″ 6-1/2″ 5-1/2″ 4-1/2″
6″152mm 5″127mm
171mm 165mm 140mm 114mm
Stroke Rated 3000 20.7 4322 29.8
2370 16.3 2558 17.6 3572 24.6 5000 34.5
SPM power psi MPa psi MPa
psi MPa psi MPa psi MPa psi MPa
Displacement
1071 hp 697 GPM 646 GPM 551 GPM 463 GPM 382 GPM 310 GPM
150
799 kW 43.97 L/s 40.76 L/s 34.76 L/s 29.21 L/s 24.10 L/s 19.56 L/s
1000 hp
※ 651 GPM 603 GPM 514 GPM 432 GPM 357 GPM 289 GPM
140 ※
746 kW 41.07 L/s 38.04 L/s 32.43 L/s 27.25 L/s 22.52 L/s 18.23 L/s
※
130
692 kW 38.11 L/s 35.33 L/s 30.09 L/s 25.30 L/s 20.88 L/s 16.97 L/s
120
639 kW 35.20 L/s 32.62 L/s 27.82 L/s 23.34 L/s 19.31 L/s 15.65 L/s
110
585 kW 32.24 L/s 29.90 L/s 25.49 L/s 21.39 L/s 17.67 L/s 14.32 L/s
100
532 kW 29.34 L/s 27.19L/s 23.15 L/s 19.49 L/s 16.09 L/s 13.06 L/s
90
479 kW 26.37 L/s 24.48 L/s 20.82 L/s 17.54 L/s 14.45 L/s 11.73 L/s
4.65 GPM 4.31 GPM 3.67 GPM 3.09 GPM 2.55 GPM 2.07 GPM
1
0.2934 L/s 0.2719 L/s 0.2315 L/s 0.1949 L/s 0.1609 L/s 0.1306 L/s
Note: a. calculated as per the volumetric efficiency of 100% and the mechanical efficiency of 90%.
b. Sign ※ shows the rated stroke numbers and rated input power corresponding to rated strokes
5
3.3 Overall dimensions

For the overall dimensions of HHF-1000 drilling pump, see the figure 2 below.
Fig. 2
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4 Use of new pump
4.1 Installation of new pump

The HHF-1000 drilling pump manufactured by our company has been completely assembled and
test-operated under load and then drained all lube from power end before being delivered to our
customers. The pump must be checked and operated according to the following methods and measures
before being put into operation. In order to prevent personal injury during the performance of any
checking and maintenance work, it must be shut down, all safety and protection device installed
on the prime mover and transmission device must be put in safe positions.
4.1.1 Requirement to foundation
The skid under the HHF-1000 drilling pump is fit for all types of installations, but it is worth to be
mentioned that although the frame with box structure at the power end has high resistances to bending,
but relatively has lower resistance against twist; therefore, the foundation under the frame must be level
and with enough strength to bear the pump’s dead load and dynamic forces exerted upon during
operation.
4.1.2 Ground installation
In ground installation, it is suggested that a underlay with at least eight pieces of 3″×12″
（76mm×305mm）boards be placed under the pump skids along the entire length，the positions as
shown in the Figure 3. The foundation under the pump skids must, at least, be 12″（305mm）wider than
the width of the pump skid runner. More solid foundations are required in case of the installation being
located in wet or marshy land.
Fig. 3
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4.1.3 Fixing installation
While the drilling pump shall be permanently installed on the structural base or concrete
foundation of a barge or drilling platform, and the pump skid shall be fastened by bolts, it is essential
that the skid must be properly shimmed to prevent the power end frame from possible distortion or twist.
The pump skid must be solidly sat down on all shims while all bolts are loose.
In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installing
shims are shown in the Figure 3 and 4. Properly shimming should be done to avoid possible twist or
distortion. All shims must exceed the full width of the skid beam flanges and have a minimum length of
12” (305mm).
When integral installation for power unit or electric motor and pump skid are required, the pump
must be fixed on the skid of the T-beam, with retention blocks rather than bolts; in this way, the drilling
pump could be a bit “floating” so as to reduce greatly the possible deformation of the pump frame
caused by the deformation of barge deck or platform.
3 4
1 pump skid 2 shims 3 T-beam 4 deck
Fig. 4
4.1.4 Installation of drive device
Whether to use V-belts or multi-row chains or universal shaft for the power transmission between
power unit and drilling pump, installation precision should be ensured for the longest service life and
minimizing the shut-down time caused by failures from the drive.
8
Upon installation of drive sheave or sprocket, make sure all antirust or greases in the hub hole and
on the fit shaft are removed completely; Burs and rough spots on the keys, keyways and shaft must be
removed so that all keys fit properly in the keyways on the shaft and drive parts.
The pinion shaft extension should be coated with light lubrication or anti-agglutination oil, and
then fit the hub of sheave or sprocket, tighten all bolts according to the following requirements:
Tightening bolts with wrench or wrench with extension pipe may lead to extra high torque,
therefore, it is imperative to keep the torque value given in the following table to tighten all bolts,
otherwise, it may damage the hub and the sheave by the exceeding tightening force, which is again
multiplied by the wedging action of the tapered surface. In addition, all bolts of hub fixing must be
tightened alternately and gradually.
Tightening Force exerted on

Pump model Hub Wrench Length
torque wrench
HHF-1000 W 813N.m 900mm 900N
4.1.4.1 V-belt drive
A. Checking sheave groove status
Before installation, check that whether the sheave’s grooves are worn out and getting rounded or
not, otherwise, the V-belt will be damaged quickly. The groove sidewall must be level and straight and
there are no extrusions.
B. Checking sheaves alignment
Having installed all belts and tensioned them to working condition, check the alignment of sheaves
finally. If the distances from one side of the two sheaves to their centerline of sheave groove are equal,
check the alignment with two tightened strings (such as the string for fishing or better for piano) along
one side of the two sheaves; one is put above the sheave center and another below the center, and then
move one of two sheaves until the strings have touched 4 points on the sheave rim, or the distances they
reach to sheave rim are not more than 0.079″（2mm）, in this way we can determine that the two
centerlines of the sheaves are parallel and their side faces are vertical to their shaft centerlines.
C. Adjustment of V-belt pre-tension
To adjust the belt tension, change/increase the central distance between two sheaves until no sag to
be found on the tensioned belt side, and the slack side is also tensioned but has a bit of sag. And then
increase a certain of central distance again, for example, if the center distance is 100” (2540mm), a 1/2”
(13mm) distance is to be increased after completion of adjustment of the central distance; again if the
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center distance is 150” (3810mm), a 3/4” (19mm) distance is to be increased.
Note: Don’t obtain belt tension by lifting the pump or by lowering the pump below ground level to
allow the belt to be tensioned by pump’s weight.
4.1.4.2 Chain drive
A. Installation
Correct installation and maintenance are important means to extend the service life of chain drive
and chains and sprockets themselves. Many factors such as the width of chain, center distance, speed
and load etc. are to be considered when determining the allowable alignment tolerance of sprockets;
since there is no perfect “operating method” to be applied, therefore, what we can do is to make the
chain alignment as exact as possible. A more precise alignment can be made with two stretching steel
wires (better for piano) along one side of the both sprockets; one is put above the centerline and another
below the centerline, and then move one of two sprockets until the strings have touched 4 points of the
sprocket rim, or the distances they reach to sprockets rim are not more than 0.079″（2mm） , in this way,
to determine the two centerlines of sprockets are parallel and their end face are vertical to their shaft
centerline.
B. Lubrication of drive chain

The lubrication system for chain drive of HHF-1000 pump is an independent system with its own
oil pump, oil tank and drive. Fill the chain box and reach marked level with lubrication oil as follows:
Ambient temperature above 0°C（32°F） SAE-30/N100
Ambient temperature below 0°C（32°F） SAE-20/N68
When ambient temperature below -18°C

（0°F）, consult the lubrication dealer for recommendations.
Refer to the general lubrication bulletin for approved lubricants and additional specifications, if
any difference exists between the recommendation in this manual and the general lubrication bulletin,
those in bulletin will take precedence.
Because the chain drive lubrication system is an independent system, so it shall be maintained as
common machinery, including:
—— Daily check oil level;
—— Daily check oil condition;
—— Daily check oil pressure, 5～15psi（0.035～0.103MPa）;
—— Check oil amount supplied to chains;
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—— Check nozzle condition on spray tube;
—— Check the working condition of oil pump drive（V-belt or chain）.
Note:
① The oil pressure can be adjusted by the pressure relief screw at the rear of pump housing.
② The oil pressure drops or is too high, indicate the suction and discharge filter screen necessary
to clean.
4.2 Requirement to suction system

The design of suction system of drilling pump must consider separate installation. The suction of
HHF series pump must have a positive head (pressure) for satisfactory performance. The optimum
pressure in suction manifold is 20～30psi（0.14～0.21MPa）for maximizing the volumetric efficiency
and wearing parts life. This positive head (pressure) can be supplied by a 5×6 centrifugal pump
（matched with a 40HP, 1150RPM motor）or a above size pump . This type of suction system requires
to start and stop automatically the centrifugal pump and mud pump synchronously. In DC electric rig,
generally, a signal can be supplied from DC control panel to actuate an electromagnetic starter.
The suction line arrangement shall be such that the charging pump can be bypassed. When the
charging pump faults or in servicing, the mud pump can work continuously. The operation without a
charging pump can be improved by replacing the suction valve spring with a weaker one.
The suction air damper is a very effective assistant device for full filling liner and dampening
suction pulsation and finally result smoother flow in discharge line.
Note: do not connect the return line of shear relief valve to the suction line, because the relief
valve actuating will cause a sudden pressure rise in suction system, while the pressure exceeds the
system pressure rating, this may results damage of manifold, air damper and centrifugal pump.
4.3 Preparation of power end

The HHF series drilling pump manufactured by our company has been completely assembled and
test operated, the lubrication oil has been drained from power end before being delivered to customer.
Before putting into use, the following must be conducted or checked:
4.3.1 Power end lubrication
Before adding lubricant open the inspection door on cover and check for possible accumulation of
condensation in oil sump, drain by removing the plug screw (No. 2 in figure 8) on both sides of mud
11
pump and flush the inner chamber, add proper type (trademark ) and quantity of lubricant in power end
according to the requirements written in nameplate riveted on frame and check oil level.
Before starting, it is also need to open the cover on rear plate and the side cover of crosshead,
add sufficient lube to bearing oil groove, crosshead oil groove, gear pair, friction pair of crosshead
and lower guide, make all friction surfaces of power end to be properly lubricated. If the drilling
pump adopted the electric oil pump built outside, it must be firstly started before starting the
drilling pump to get satisfactory lubrication performance.
Recheck the oil level after operating the mud pump about 15 minutes, stop pump and waiting about
5 minute for oil level lower and quiet, check the oil level gauge (No. 1 in figure 8), about 10 liters oil
must be added generally, because of a certain amount of oil remained in crosshead and frame cavity.
4.3.2 Check and installation of crosshead extension rod and stuffing box seals
As shown in figure 5, remove the stuffing box and baffle plate (1), and crank the mud pump to
make the crosshead at the front of stroke, check the bolts for tightness. If the cleanness degree between
crosshead front and extension rod and the tightness of bolts not conform to requirements, remove the
crosshead extension rod, clean the front of crosshead and the face of extension rod thoroughly, insert the
alignment boss on extension rod into the alignment bore on crosshead and tighten the fixing bolt (2) to
350～370ft. lbs（475～500N.m）, finally lock them with wire.
7 12 4 1
11
8
2 A 3
5 6 5 6
7
9
10
Fig. 5
12
Thoroughly clean the face of baffle and frame (at place A in figure 5), install the gasket (3) and
screws (10), tighten them to 90～120lbf. ft（120～160N.m）.
Clean the face and ID of baffle plate, clean the OD and flange of stuffing box, coat the OD of
stuffing box with light oil and install O ring (4), install the stuffing box into baffle plate firstly, install
the seals and end cover in sequence, make sure that the oil return hole of stuffing box and the drain hole
of end cover shall be located just bottom, tighten the fixing screws to 12～18ft.lbs（16～24N.m）.
In stuffing box, the packing assembly is consisted of a double lip oil seal (6), oil seal ring（7）、“O”
ring（12）, “O” ring（8）and retainer spring（9）etc. Install them as following:
1) Take out the spring (5 ) from the double lip oil seal（6）, install the oil seal on the OD of
crosshead extension rod with lip towards power end, replace the spring (5) on oil seal lip and slide the
oil seal into the position in stuffing box. Refer to below note.
2) Install the “O” ring（12）into oil seal ring（7）, place it on OD of crosshead extension rod and
push them into stuffing box.
3) Install the “O” ring（8）into groove of stuffing box。
4) Install the double lip oil seal shown as the right end in figure 5, the installing process is as
described in 1) above.
Note: the double lip oil seal nearby the power end can be replaced by single lip oil seal, but the oil
seal close by the fluid end must be double lip oil seal only.
5) Install the retainer spring（9）.
Note: must be sure that, the pressure spring（5）do not slip out from the groove of oil seal lip when
severe scoring on extension rod appears. Coat the OD of extension rod with light oil to facilitate the
installation of packing assembly.
4.4 Spray pump system

The spray system consists of spray pump assembly, water reservoir, spray tubes etc. It is used to
flush, lubricate and cool the liner and piston while pump running.
The spray pump is a centrifugal pump, driven by pinion shaft via pulley (or driven with motor
independently), water is used as cooling lubricant. In all operating time the cooling fluid must be
supplied sufficiently to piston and liner, stoppage of cooling fluid will result in instant damage of piston
rubber and liner.
13
The HHF-1000 drilling pump manufactured by our company adopts stationary spray tube as shown
in figure 6, including holder (1) mounted on frame, pipe nipple（2）and spray tube（3）, which spray
2
1
3
Fig. 6
cooling fluid on piston and liner. Adjust the cooling fluid amount supplied to spray manifold to ensure
that the cooling fluid directly spray to piston.
The cooling fluid is pumped to manifold on left (right) frame wall via spray pump（No. 3 in figure
8）from water tank（No. 5 in figure 8）, adjust the ball valve （No. 4 in figure 8） to supply as much
cooling water as possible to spray piston and liner but without splashing back on the crosshead
extension rod and baffle plate, otherwise, a few water will penetrate stuffing box to pollute lubrication
oil in power end.
The cooling fluid flows from drain hole on frame into sediment chamber of water tank, when the
cooling fluid overflow through filter screen, solids settled and more foreign matters are caught by filter
screen, as shown in figure 7.
Check the cooling fluid frequently for cleanness condition, clean and flush water reservoir and
replace cooling fluid as required, because the sand increasing in contaminated fluid will result in
premature damage of piston and liner or spray nozzle jam.
1.to spray pump suction pipe

2.filter screen
3
3.drain hole, frame
4. sediment chamber
2
4 5.drainage port
1 5
Fig. 7
14
Fig. 8
4.5 Checkup in fluid end

As mentioned above, the HHF series drilling pump manufactured by our company has been
completely assembled and test operated before being delivered to customer, consider the possible
disassembly in transportation and various working condition, before putting in operation, the following
checkup must be carried out:
4.5.1 Valve and seat
Remove the three valve pot covers, three cylinder heads and cylinder head plugs, inspect
respectively the installing position of suction/ discharge valves and seats for correct installation, if they
do not conform requirements, and redo the assembly and adjustment according to requirements written
in section “Maintenance of fluid end”. While the suction manifold and discharge manifold have been
installed well, feed the suction manifold and cylinder block (fluid end) with water or drilling fluid to
bleed air completely, then install the valve pot covers and tighten them.
4.5.2 Liner and piston
Inspect if the liner and piston have been installed on drilling pump already, whether they meet the
15
requirement of actual working condition or not, if not, replace them according to requirements written
in section “Maintenance of fluid end”.
4.5.3 Suction flange
The suction flange is a connection flange machined specially to match the suction manifold, bore
diameter 12″（305mm）. O-ring is used for connection seal, before assembly, the O-ring groove and
flange end face must be clean completely, and then tighten the connection bolts to 360～490ft.lbs
（490～665N.m）.
4.5.4 Discharge manifold
The discharge flange is one of 5 1/8″(127mm)5000psi. take down the flange and gasket ring, weld
the flange to discharge line (user conducts the welding himself) , tighten the connection bolts and nuts
evenly in a criss-cross manner to 1200～1600ft.lbs（1625～2165N.m）torque. If the other end of
discharge manifold is not connected to mud line, plug it with blind flange, tighten the connection bolts
as described as above
4.5.5 Assistant manifold
3-8NPT
1
R1 1/2 I
I
6 7
4 5
2-11 1/2NPT
Fig. 9
The assistant manifold is shown in the figure 9. It is installed on the discharge manifold and
opposite to the discharge filter assembly. This assistant manifold is connected with pulsation dampener
16
(1); and it has a 3-8NPT and a 2-11 1/2NPT outlets, the two outlets are connected with shear relief valve
(3) and pressure gauge (2) respectively.
Note: when the pressure gauge connection thread is R1 1/2, an X-over sub will be used.
The assistant manifold and discharge manifold are connected by flanges; before installation, clean
thoroughly the flange gasket ring groove and then put in the gasket ring (4), and tighten the connection
nuts (5) to the torque 1200～1600ft.lbs（1625～2165N.m）. To ensure an uniform force is exerted on the
gasket ring connections, tighten the nuts evenly with criss-cross manner
The shear relief valve (3) is installed on the assistant manifold for the purpose of protecting the
pump from pressure exceeded the rated value to guarantee safety of the mud pump. The shear relief
valve must be installed so that it will be directly exposed to mud tanks; and no gate valves may be
installed between the relief valve and the discharge line. Pipe the outlet of the relief valve directly to the
mud tank by seamless steel pipe and with as few turns in this line as possible. If a turn is necessary, the
elbow bend should be > 120°. It is not allowed to pipe the outlet of the relief valve to the suction pipes
of the pump.
The relief valve setting shall be changed according to the max. pressure rating of particular liner
size, which are marked (written) at the valve body. Change the setting of relief valve as each liner size
change, when setting relief valve, just insert the shear pin in corresponding hole.
Note: only one shear pin shall be inserted in hole, and don’t use Allen key, welding rod or
other material to replace shear pin, as this will affect the rating of relief valve and may result
accident.
The bottom flange of KB-75 air dampener (1) is equipped with R39 gasket ring (6); before
installation of air dampener, clean the gasket ring and groove thoroughly and after installation, tighten
the nuts (7) to the torque 750～850ft.lbs（1020～1150N.m）. To ensure balanced forces to be exerted, all
nuts shall be tightened evenly in a criss-cross manner.
Before starting drilling pump, precharge the pulsation dampener to no more than 2/3 of the pump
discharge pressure, the maximum precharge pressure is 650psi（4.5MPa）. The pulsation dampener shall
be precharged with nitrogen or air. Do not precharge with oxygen, hydrogen or other flammable and
explosive gas.
The charging will be conducted with a set of charging equipment (air damper charging hoses
assembly) provided together with the pump, as shown in Figure 10, and the operation process are as
follows:
17
1
2 3 4 5 6 7
Fig. 10
1-switch on nitrogen bottle 2-nut 3-sealing connector 4- connector 5-gasket 6-screw plug
7-shutoff valve, dampener 8-hose
1 Remove the pressure gauge guard of damper, loosen the discharge valve cap about 1/4—1/2 turn,
discharge remaining pressure to zero, take down the cap and plug of discharge valve .
2 Connect the hose to nitrogen bottle and air dampener discharge connectors.
3 Open the shutoff valve on dampener
4 Open the valve on nitrogen bottle, and use this valve to adjust the nitrogen gas flow to dampener
5 When the pressure gauge reading reach to required value, close the valve on nitrogen bottle.
6 Close the shutoff valve on dampener.
7 Take down the inflating hose, cover the pressure gauge guard again, re-install the cap and plug of
discharge valve.
Warning:
A. It is used the compressed nitrogen or air only, prohibit to use flammable and explosive
gas as oxygen, hydrogen etc.
B. When servicing the dampener, its internal pressure must be zero, at the same time, the
drilling pump pressure must be zero also. Don’t judge the pressure with pressure gauge reading
only; you must open the discharge valve cap to release pressure. When the residual pressure is low,
the pressure gauge will be no indication, but this low pressure may result accident still.
18
5 Lubrication
Sufficient lubrication to movement components is very important, it affect directly the service life
of machinery, for the purpose of long time running without trouble, the power end must be checked and
maintained periodically, to ensure that all movement parts are lubricated with proper clean lube.
5.1 Minimum operating speed

To lubricate whole power end, a combination of splash lubrication and pressure lubrication is
adopted for HHF-1000 pumps. When a gear oil pump is driven mechanically (except driven by a
electric motor), the pressure system adopted, in fact, governs the minimum SPM of drilling pump. As
for the pressure lubrication systems adopted for HHF-1000 pump, it can operate at a minimum SPM of
25; at this time, the lowest oil pressure is 5 psi (0.035 Mpa).
Note: The pressure lubrication oil pump can be installed outside of drilling pump and driven by
V-belt/ individual motor, or installed inside of drilling pump and driven by big gear ring. When the later
installation is adopted, the rotation direction of the pinion shaft shall be as shown in figure 11.
2 1
1.pinion shaft
2.big gear ring
3.oil pump gear
Fig. 11
5.2 Flow-controlled splash lubrication system

The flow-controlled splash lubrication system is regardless of the type of oil pump for lubrication
of HHF-1000 pump. In the flow-controlled splash system, the big gear ring brings the oil up from the
sump; and when it mesh with the pinion, the oil is squeezed out and splashed to various oil grooves and
oil cavities in the frame. With reference to figure 13, the oil is thrown into the groove (7) and flows
through pipe (8), to the bearings on the two sides of the pinion shaft.
The passage that oil flows from the top of the crosshead guide into the crosshead bearings is shown
in figure 12. The oil accumulated in oil chamber above the crossheads flow through oil nozzle (1), into
19
the crosshead pin baffle, and then to oil passages (5) to lubricate crosshead bearing. There are two oil
passages (5) symmetrical to axial line and machined on the crosshead pin, which enable its oil bores to
be aligned even if the crosshead rotates 180°. This permits the installation of crosshead being possible
from either direction of the frame’s two sides.
2 4
3
5
Fig. 12
5.3 Pressure lubrication system

The pressure lubrication system adopted for HHF-1000 drilling pump is equipped a lube oil pump,
as shown in Figure 13; in this system, the oil is sucked in through the suction filter (1) and then through
the connector block II (2), distributed to the pinion shaft nozzle (3A), main bearing oil-pipe (4) and the
connector block I (4A) for crosshead, again through the block I (4A) distribute oil to the crosshead,
crosshead bearing and extension rod.
A pressure gauge (5) is installed on the back base plate of the frame to show the oil pressure in the
connector block II. It is obviously that the pressure reading changes with the speed of the pump.
However, if a sudden pressure drop or increase occurs, the reasons must be found according to the
section on Maintenance of lubrication system.
A pressure relief valve (6) is installed on the connector block II (2) to prevent the pump and its
drive from possible damage caused by excessive pressure. The relief valve is preset to 80 psi (0.55 MPa)
and then locked up to avoid the preset pressure changing.
20
4
1 3A
2
8
6
9 3 3A
8 7 4A
5 4
2
9
Fig. 13
There are two modes of lubrication oil pump arrangement for option—“built-in” and “built-out”. If
user do not requested, ordinarily, we arrange them to “built-in” mode, no matter what mode adopted, the
internal lubrication piping are same.
When the lubrication oil pump is “built-in” installed (No. 9 in figure 13), the oil pump must be
located well, the oil pump gear shall be parallel to big gear ring of drilling pump and meshed properly,
the backlash of gears shall be 0.0236″～0.0354″（0.60～0.90mm）.。
When the lubrication oil pump is “built-out” installed, the general lubrication piping is shown as in
figure 14 and 15.
21
Figure 14 is a typical mode for oil pump drive, the oil pump is driven by pinion shaft via V-belt,
the oil pump（1） is connected to lubrication piping via connector block and tube. The V-belt (2) should
not be tensioned too much to prevent the premature damage of oil pump. To prevent personnel injury,
the belt drive guard (No. 3 in figure 14) must be installed well.
Fig. 15 show the mode of oil pump driven with motor. The connection between lubrication oil
pump and lubrication piping of drilling pump is basically same to former, before starting the drilling
pump, the lubrication oil pump must be firstly started to make all movement parts sufficiently
lubricated.
3 2 1
Fig. 14
22
1 pump set skid 2 motor 3 gear oil pump 4 pressure switch 5 oil suction filter
6 magnetic filter 7 oil distributor 8 drilling pump 9 oil pressure gauge
Fig. 15
23
5.4 Maintenance of lubrication system

Sufficient lubrication of all movement parts is the most important factor to extend the service life
of the pump; to maintain carefully the lubrication system is the duty of operators. In fact, a good or poor
maintenance of the lubrication system determines a long or short trouble-free service life of drilling
pump.
The recommended lubrication oil are as follows; and also shown on nameplate fixed on the pump
frame. All data recommended are the results of long-period tests in the oil field; therefore, any
substitution of lubrication oil could only be used for emergency conditions.
5.4.1 Lube spec.
We recommend that, you prefer to adopt extreme pressure (EP), non-corrosive and anti-foaming
gear oil as follows:
Ambient temperature: +30°F～+ 155°F （-1°C～+ 68°C）
AGMA 250.04EP（6EP）or ISO VG320
Ambient temperature: 0°F～+ 80°F （-18°C～+ 27°C）
Ambient temperature: -20°F～+ 40°F （-29°C～+ 4°C）
Oil sump capacity: 75 US gal（284L）
5.4.2 Maintenance work
Every shift, check the oil level and maintain the level at the FULL position; in view of oil level
compensation, it is allowed to run the mud pump for 5 minutes at a slow speed and make sure the oil
level at the stipulated position.
At least weekly do water draining, remove the 2 1/2″plug screw at the bottom of frame to drain
water accumulated.
Settling chamber is located at crosshead guide portion, to settle the dirties splashed in. The
drainage cover of settling chamber is located at the frame sides under crosshead cover, open it, the
sediment can be eliminated. Check monthly, remove the drainage cover and drain the dirty oil
24
containing sediment, this may lose about 15 US gal lube, oil supplement shall be done in time.
Check twice every 6-month, if the oil has any abrasive particles and corrosive compounds in it,
drain all oil and flush the oil sump before filling new oil. The oil drains are located on side of the pump
frame. During flushing, thoroughly clean the oil grooves and the oil chamber above the crosshead
guides, and also clean or replace the filter element of suction filter, and clean the suction filter screen.
Before filling new oil remove the cover from settling chamber and clean out sediments.
Regularly check the condition of the lube and replace in time if it is contaminated by moisture,
enter of water, dust and mud.
In case of oil pressure drop occurs; check the following items:
—— Whether the suction screen is jammed or not
—— Whether the oil level is too low or not
—— Whether the V-belts are slipping or not
—— Whether the connectors are loose or broken or not
—— Whether the oil pump is worn or damaged or not
—— Whether the relief valve faults or not
In case of oil pressure increase abnormally; check the following items:
—— Whether the oil loop is blocked or not
—— Whether the sediments make oil too viscous or not
—— Whether the relief valve functions or not
—— Whether the pressure gauge is damaged or not
—— Other things
6 Maintenance and Assembling of Main Components
6.1 Power end

Routine checkup to power end is the most important work of preventive maintenance. It can find
various troubles and eliminate them in time. This work can be done while the drilling operation stops or
the drilling rig moving.
25
6.1.1 Check the tightness of main bearing bolts
Tighten the main bearing bolts to 11923N·m
6.1.2 Check lock wire
Check all bolts or screws, including main bearing bolts, eccentric bearing retainer bolts etc,
retighten them and replace their lock wire, about their tightening torque, refer to the section for
crankshaft assembly.
6.1.3 Lubrication oil piping
Check all oil lines to ensure them complete and pass free, check the suction line of oil pump and
ensure no damage and deformation.
6.1.4 Suction filter
Check the suction filter for proper condition, clean and replace if necessary
6.1.5 End cover, main bearing
Remove the end cover for main bearing, check the tightness of main bearing bolts and bearing
roller’s condition, clean any dregs and foreign matters.
6.1.6 Teeth of pinion
Check the gear pair for abnormal abrasion. At running in period, there are some spot on tooth face,
this is “initial spot corrosion”, no harmful to gear service life. If you find that the spot corrosion expands
continuously during routine inspection, contact manufacturer immediately, in order to examine the gear
thoroughly.
6.1.7 Crosshead pin bolts and crosshead guides
Remove the crosshead cover to check the bolts and lock wire, tighten the crosshead pin bolt (No. 3
in figure 12) to 500～550N.m.（while inspecting the middle crosshead pin, you can remove the rear
cover and turn the connecting rod (eccentric) to outside dead center）.
You should use the wrench with torque indicator while tightening bolts, don’t exceed the torque
stipulated above.
26
If abnormal abrasion in crosshead and guide appears, replace them at once, because this may result
damage of bearing and other parts, excessive abrasion may cause premature wear of liner and piston.
6.1.8 Lubrication oil and oil sump
Check the condition of lubrication oil and oil sump according to the chapter of lubrication system
maintenance in this manual.
6.2 Rolling bearing

HHF series drilling pump adopt rolling bearings. The rolling bearings are precision mechanical
components, must be carefully maintained in order to keep high load capacity and long service life.
The main bearing for crankshaft is spherical aligning roller bearing; the pinion shaft adopts short
cylindrical roller bearing; the eccentric bearings are single row short cylindrical roller bearing with rib,
convenient to assemble and disassembly; the crosshead pin bearings are double row long cylindrical
roller bearings.
The inner ring and outer ring of all bearings are very exactly machined, the movement clearance of
bearing is very small, need not to adjust specially after assembling. The bearing must be used and
replaced with a whole set. Even though only one part of a bearing is failure, the whole set of bearing
(including inner ring, outer ring, roller and roller cage) must be replaced. If there is extra clearance,
wearing in ring raceway, spot corrosion or shell off on rolling element appeared, this indicates bearing
failure, the bearing must be replaced as soon as possible.
Assembling (installing) a rolling bearing to shaft, the heating assembly (shrinkage) method should
be adopted. The damaged bearing or inner ring need be removed from shaft, this can be done by strike
with copper rod and hammer, or gas cutting but take care to avoid damage to shaft. Generally, we adopt
oil bath heating to install bearing, the heating temperature is controlled under 300℉（149℃）. Oil and
oil pan used for heating should be clean, the inner ring of bearing must be underlayed in oil pan while
firing directly under oil pan, and the oil bath heating for bearing can not exceed 3 minutes commonly.
It is not suitable to heat bearing with flame gun. In special case, it must be performed by salted gas
welder, and the flame must be at least 6″（150mm）away from bearing, and the heating temperature can
be tested by temperature testing gun. The overheating of bearing must be avoided, otherwise, the
bearing shall be softened because of temper.
Once the bearing is heated and installed on shaft, you should wait it to cool down naturally in place,
don’t water it to speed cooling down. The quick cooling will result “heat crack” damage in inner ring,
outer ring and rolling element.
Don’t knock bearing with steel hammer, while installation, you can use wood hammer or copper
27
rod to knock bearing gently and make it in place.

For convenience of installation, commonly, coat the shaft journal and housing hole with lubricant
or anti-agglutination compound.
While installation, take the bearing out from casing box, prevent dust and foreign matter entering
bearing, remove the packing antirust, clean completely the bearing with clean kerosene or other solvent.
6.3 Pinion shaft assembly
Fig. 16
The fits between pinion shaft and bearings are shown in table Ⅲ.
Table Ⅲ
Description Position Value
T0.002″～T0.0041″
Bearing inner ring to shaft journal A
T0.050mm～T0.105mm
L0.0007″～L0.0045″
Bearing outer ring to bearing carrier bore B
L0.018mm～L0.115mm
L0.0027″～L0.0071″
Bearing carrier to frame bore C
L0.069mm～L0.180mm
In the above table, T indicates interferences, L indicates clearances.

The pinion is an integral part of the shaft. The running clearances of bearings are predeterminated
by their precision fits to the shaft and the bearing carrier. When performing maintenance or overhaul,
the fits shown in table Ⅲ shall be obtained
It is needed only to install the bearing inner ring and wearing sleeve (15° chamfer towards outside)
28
to the pinion shaft, the assembly of pinion shaft is now finished, and it can be installed to pump frame
from either side of frame assembly（see figure 16）.
When installing the pinion shaft into the frame assembly, observe the following precautions:
A. Ensure the bearing carrier gasket（6）and end cover (oil seal carrier) gasket（5）are in place and
in good condition.
B. When installing the bearing carrier（7）and end cover（4）, make sure the oil grooves are
positioned correctly at just down and aligned to drain hole. Besides, the oil collecting box on bearing
carrier must be positioned at just down.
C. Remove burrs, nicks or groove on wearing sleeve（3）, then install the end cover（4）in place.
While installing, take care to prevent the oil seal lip from damage by the sharp edges of keyway, when
the oil seal passing through wearing sleeve, don’t allow the oil seal lip turn on wearing sleeve.
D. Tighten the bearing carrier bolt（12） to torque of 140～165ft.lbs (190～225 N.m).
E. Check the inner and outer ring and rolling element of pinion shaft bearing for good condition. If
there is any wear and tear, galling, flaking, grooving, or the radial clearance exceeds 0.0079″~0.0118″
（0.20~0.30mm）, it is recommended to replace the whole set of bearing.
6.4 Crankshaft assembly

The crankshaft assembly consists of the crankshaft, connecting rod (eccentric strap) and bearing,
big gear ring, main bearing etc. The running clearances of bearings are predeterminated by their
precision fits to the shaft and respective bores. When performing any maintenance or overhaul, make
sure the fits shown in table IV shall be obtained.
Table Ⅳ
Description Position Value
T0.00023″～T0.0047″
Main bearing inner ring to shaft journal A
T0.060mm～T0.121mm
0″～L0.0043″
Main bearing outer ring to bearing carrier bore B
0mm～L0.108mm
Bearing inner ring (connecting rod) to eccentric T0.0051″～T0.0091″

C
wheel OD T0.130mm～T0.23mm
Bearing outer ring (connecting rod) to connecting L0.00094″～T0.0040″

D
rod bore (big) L0.024mm～T0.102mm
Inner bore of big gear ring to wheel hub OD E T0.003″～T0.010″
29
T0.076mm～T0.256mm
L0.002″～T0.002″
Main bearing carrier OD to frame bore F
L0.05mm～T0.05mm
Outer ring of crosshead bearing to connecting rod T0.00047″～T0.0031″

G
bore (small) T0.012mm～T0.079mm
T0.00098″～T0.003″
Inner ring of crosshead bearing to crosshead pin H
T0.025mm～T0.076mm
In the above table, T indicates interference and L indicates clearance.

The crankshaft assembly is assembled as follows, (refer to Figure 17):
A. Assembly of big gear ring (gear rim)
Clean thoroughly the aligning and mating faces of the big gear ring and the crankshaft flange, and
heat the big gear ring to 176°F～248°F（80°C～120°C）and keep heating for one hour, and then install
it on the crankshaft flange with shrink fit. When the temperature dropped down to room temperature,
tighten the locknuts (19) and bolts (11) evenly with criss-cross manner to the torque of 1810 ft-lbs
（2455N·m）. Check the radial and end run-out of the big gear ring after assembly by the ways as
follows: first mount the crankshaft into the frame assembly, and then rotate the big gear ring and
measure its radial run-out on gear ring top circle directly by a dial indicator. While measuring the end
run-out, because of the running clearance of main bearings, it must be measured simultaneously at the
shaft end and gear ring end face by two dial indicators; therefore, the actual end run-out of gear ring at
any point is the difference of the two readings.
B. Install the inner ring of the eccentric bearing to the crankshaft eccentric wheel by shrink fit and
mark the matching bearing pair well; first install the bearing in middle and then at both sides, while
installing the inner ring of the right eccentric bearing, the locating ring (7) should be first installed.
Tighten the allen screws (28) to the torque 44～66ft.lbs（60～90N.m）and lock them with steel wires.
C. Heat the big end of connecting rod to 176°F～248°F（80°C～120°C）and install the outer ring of
eccentric bearing, and mark the the matching bearing pair well; When the temperature dropped down to
room temperature, install the outer retainer (5) and keep its oil scoop positioned at the bottom and
tighten the bolts (20) evenly to the torque 44～66ft.lbs（60～90N.m）and lock them with steel wire.
D. When installing the outer ring of crosshead bearing, you had better adopt refrigeration
installation method, deeply freeze the outer ring of crosshead bearing with dry ice（CO2）, then press it
into the bore of eccentric strap, certainly, if impossible, you can install with shrink fit, heat the small end
of eccentric strap to 176°F～248°F（80°C～120°C）, then install the outer ring into the bore of eccentric
30
strap.
E. Install the eccentric straps on the inner rings of eccentric bearings respectively, and install the
inner retainer ring（4），tighten the bolt（20）evenly to torque 44～66 ft .lbs（60～90 N. m）and lock
them with steel wire.
F. Firstly install the main bearing in bearing carrier with shrinkage method, then install them
together on crankshaft with shrinkage method too. When the temperature drops to room temperature,
install the retainer ring（14）and baffle plate（15）respectively, tighten the bolt （20）evenly to torque
44～66 ft .lbs（60～90 N. m）and lock them with steel wire. Before performing shrink fit, install the
bearing spacer（12）firstly.
Fig. 17
6.5 Installing crankshaft assembly in frame

In order to obtain a more precise fit between the main bearing carrier (L and R) and frame bore,
perform the installation according to the procedures outlined below:
6.5.1 Before hoisting and installing the crankshaft assembly, place a piece of wood between the
small end (eye) of eccentric strap and crosshead guide (see figure 19) to protect the crosshead guide
from scoring or gouging as the straps are sliding into position .
6.5.2 Rotate the main bearing carrier so that its two symmetry planes are parallel with the main
31
bearing bolt holes and provide clearance for the main bearing bolts to ensure the main bearing bolts to
pass in; and slowly lower the crankshaft into position.
6.5.3 After placing the crankshaft in the frame and before installing the main bearing caps, check
the rollers in main bearings to assure that each row of rollers in each bearing is equally loaded. (If the
roller is loaded, it will become tight). Tighten the main bearing bolts only while the numbers of inner
and outer rollers supporting the weight of crankshaft are equal (tight roller number). Because of
tolerances etc, the total number of tight rollers may vary slightly between individual bearings.
4 5
3 6
(0.60mm)
2 7
1
(0.50mm)
1 adjusting shim 2 main bearing cap 3 fuse wire 4 main bearing bolt 5 main bearing
6 main bearing carrier 7 crankshaft
Fig. 18
6.5.4 Install and shim the main bearing caps to obtain a 0.002″～0.004″（0.05mm～0.10mm）
interference （redundancy）and preload on the main bearing carrier. The preload is obtained by placing
correct amount of shims under the main bearing cap, the required amount of shims is determined as
follows, (see Fig. 18):
A. Install 0.50mm thick shims under both ends of the main bearing cap；
B. Place a piece of lead wire (fuse) in the middle area between ID of bearing cap inner and OD of
bearing carrier；
C. Tighten the main bearing bolt to torque 11923N.m；
D. Remove the main bearing cap and measure the thickness of lead wire (fuse wire)；
32
E. The interference（redundancy） of main bearing carrier is 0.002″～0.004″（0.05mm～0.10mm）；
F. Actually required thickness of shims is calculated from the formula as below:
Thickness of shims required = 0.50mm - thickness of lead wire compressed - interference of main
bearing carrie 0.05～0.10mm (that is F=A-D-E)
Note: Because of machining tolerance difference in left and right main bearing carriers, it is
necessary to measure and determine the shims thickness required for both sides respectively. And then
place the shims under the main bearing caps according to the thickness above-determined separately,
tighten all main bearing bolts to the torque 11923N.m. Recheck the load condition of inner and outer
row roller of each main bearing as mentioned above, to ensure each bearing being loaded equally.
6.6 Installation of crosshead guide

6.6.1 Thoroughly clean and remove dirty, burrs and rough edges from both sides of the crosshead
guides and frame bores where the guides fit.
6.6.2 If you want to reuse old guide, check whether it is worn and scored or not, otherwise, replace
with new one.
Note: For HHF-1000 drilling pump, the upper and lower guide is not interchangeable, the
upper guide is made thinner than lower guide, its rear has bigger chamfer and has oil hole at
middle part.
6.6.3 Install upper and lower guides, tighten the guide screw to torque 150～200ft. lbs (200 N.m～
270N.m).
6.6.4 Check between frame and guide at point A (see figure 20, A) with 0.002″(0.05mm) feeler
gauge, to ensure guides fit into frame and no gap existed.
6.7 Installation of crosshead

The crosshead can be installed through the front (fluid end) or the rear of crosshead guide (power
end), refer to Fig. 19. When installing, observe the procedure outlined below:
33
1 2
3 4 5
1 connecting rod 2 upper guide 3 wood block 4 lower guide 5 crosshead

Fig. 19
6.7.1 Thoroughly clean all dirty, burrs and rough edges from the OD of crosshead, Id of crosshead
guides and crosshead pin holes, wipe dry the taper pin hole so that taper hole connection will make up
metal to metal, (see note below).
6.7.2 Position the small end of connecting rod at the opening in the side of crosshead guide. Bolck
the connecting rod so that the crosshead will clear the “eye” as it is sliding into position where the
crosshead pin holes are in alignment,（see Fig. 19）.
6.7.3 Install the left crosshead firstly. Rotate the crankshaft assembly to move middle connecting
rod going into crosshead, at this time, the right connecting rod comes back, remove the mud baffle plate
(see No. 1 in Fig. 20 ), push the right crosshead towards the extension rod chamber to provide enough
space for middle crosshead installation, then install the right crosshead.
Note: If the old crosshead is reused, check the working surface for wearing and scoring. If
necessary, the crossheads may be switched to opposite sides of pump , namely exchange the left and
right crossheads to another bore , but, before installation of baffle plate (retainer) of crosshead pin, don’t
install the crosshead pin into the taper hole.
6.7.4 Install the crosshead pin retainer（2）and bolts（3）
、（4）, align the crosshead hole to “eye ”of
connecting rod, hand push or knock lightly the big end of crosshead pin, make it going into the taper
hole. Place adjusting shims between crosshead pin and its retainer (baffle plate), (for each set of
crosshead hole and crosshead pin, the thickness of shims required is determinated and not
interchangeable, otherwise, trouble may occur ). Then rotate the crosshead pin to make the 8 threaded
holes on retainer and the threaded hole under retainer alignment, hand screw in the 6 pieces of bolt (4 )
34
and 2 pieces of bolt (3 ) refer to Fig. 20 and 20A. The oil groove on retainer (2) must be upwards
positioned.
8 5 4 2 1
5
4
7 A 6 3
Fig 20 Fig 20A
Tighten the retainer bolts evenly to torque 165～175ft.lbs（225～240N.m）and lock them withsteel
wire. Do use torque wrench and don’t exceed the torque value specified above
Note: Steps for pulling out the crosshead pin: Remove the 6 bolts (4) and screw two of them into
the “jack screw” holes (5); tighten the two jack screw bolts until the crosshead pin breaks loose.
Remove the crosshead pin retainer plate (2) and bolts (3), and then take out the pin from the hole.
6.7.5 Check the running clearance between crosshead top and upper guide（8）with longer feeler
gauge, the clearance is 0.0177″～0.0256″（0.45mm～0.65mm）, check with long feeler gauge over
entire surface of crosshead.
Note: Over-tightening the bolts (4) of crosshead pin retainer plate will cause deformations of
crosshead outer contact arc-face and thus increase eccentrically-worn; at this time, the bolts (4) for the
crosshead pin retainer plate must be loosen and retighten them according to the torque specified in
5.7.4.
6.8 Check crosshead alignment

In order to let the piston moving correctly in the liner, the crosshead must travel horizontally along
the centerline of the frame hole. To check and align the crosshead as follows:
6.8.1 Remove the packing box from mud baffle plate, but don’t remove mud baffle plate (see Fig.
20).
6.8.2 Put the crosshead at the front of stroke, measure accurately the distance from mud baffle plate
35
bore to the extension rod top and bottom with inside caliper or telescoping gauge and micrometer.
Compare the two sizes measured to determine the position of extension rod relative to the centerline of
the bore.
6.8.3 Crank the pump to put the crosshead at the back of stroke, do measurement as above
mentioned, compare the sizes measured with the sizes measured at front to determine whether the
crosshead runs horizontally or not.
6.8.4 If the coaxiality of extension rod exceeds 0.015″(0.381mm) at the bottom of the bore, it is
necessary to shim the lower crosshead guide to align the extension rod to bore centerline. At the same
time, ensure there is proper clearance between crosshead top and upper guide. Generally, because of the
movement angle of connecting rod, the lower guide is loaded heavier than upper guide, especially the
rear part of lower guide is exerted most heavy, hence the wearing is severe. So if you can shim the
crosshead guide firmly, you had better shim the guide a little inclined.
When shiming the guide, the clearance between crosshead top and upper guide should not be less
than 0.0177″(0.45mm). because of the running feature of triplex pump, when the pump rotates
clockwise, the force from crosshead exerts always on the lower guide, so a little bigger clearance of
crosshead is allowable.
Note: Due to the reason of power, if the drilling pump must rotate counterclockwise, the force from
crosshead will exert on the upper guide, therefore, the clearance between upper guide and crosshead
must be controlled within 0.098″～0.0157″（0.25～0.40mm）.
6.8.5 The shim for guide should be long enough to reach completely across the guide, and cut tabs
on the shim side and exceed over the frame supports (refer to installation of crosshead guide, No 3 and 4
items).
6.9 Maintenance of fluid end

The higher pressure of present-day drilling requirement results the damange of fluid end often and
often. More and better maintenance to fluid end is necessary to obtain reasonable service life.
A few of the obvious points are described as follows:
1 Before starting the drilling pump, make sure all valves on the discharge side are opened. While
the valves are closed, the pump starting will exert an impact stress to the fluid end and may cause
fatigue cracks; and finally the fluid end will be rejected by corrosion fatigue failure if the condition
continued.
2 When the prime mover (such as diesel engine, electromotor and drive) is running at high speed,
do not engage drilling pump clutch, otherwise, it will cause undesirable shock loads against both power
end and fluid end.
3 Properly maintain the pressure relief valve and set pressure according to the liner size being used
36
for ensuring the relief valve release the pressure while overpressure occurs
4 Don’t operate the drilling pump for an extended period if a severe fluid knock is present.
Properly maintain the fluid ends for storage. When the drilling pump is to be hut down or not operated
for a period of 10 days or more, it is recommended that the fluid end parts such as piston, piston rod,
liner etc be removed from pump and the fluid end be flushed thoroughly with fresh water, and then
wiping them clean after flushing; grease all parts removed and all machined surfaces. This will not only
extend the life of the fluid end but also protects the expendable in good condition for installation when
the pump will be operated again.
The fluid end assembly for triplex pumps consists of 3 forged cylinder blocks, complete with liner,
valve pot cover and cylinder head, a suction manifold and a discharge manifold etc.
Most parts of fluid end are designed as metal to metal installation, this lightens the abrasion caused
by high pressure fluid in today drilling. Based this reason, for the reliable seal of fluid end, all parts
must be cleaned thoroughly before assembling, any defect or bug, such as burrs, nicks and rust spot are
not permitted to present.
6.9.1. Cylinder block
The structure of cylinder block is shown in Fig. 21, the dimensions are shown in Table Ⅴ.
The three independent cylinder blocks (3) are connected to the power end frame through studs (5),
and aligned by the pilot boss on wear plate of cylinder block to the power end frame bores. While
installing, all burs, dirts and gouging etc should be removed completely from wear plate outer boss and
frame bore’s mating faces, otherwise there will be warping or misalignment.
Table Ⅴ
Position Dimension Position Dimension
8.7551" ～8.7598" 6.0084" ～6.0124"
A E
222.38 mm～ 222.50 mm 152.614 mm ～152.714 mm
7.7551" ～7.75787" 5.6217" ～5.6268"
B F
196.98 mm ～ 197.05 mm 142.79 mm～142.92 mm
13.3740" 4"
C G
339.7 mm 101.6 mm
6.7752" ～6.7803" 4.5"
D H
172.09 mm ～172.22 mm 114.3 mm
37
Fig. 21
6.9.2. Suction manifold
The suction manifold (3) is connected with each cylinder block by bolts and sealed through O-ring
(4) in the connection flange. Before installation, thoroughly clean O-ring grooves and sealing surfaces
in the cylinder block, and then put the O-ring; to ensure good sealing, the flange connection must be
made up ‘metal to metal’, therefore, any nicks, grooves or galling on the sealing surface must be
repaired. Refer to the following section 6.10 Welding and Repair, of this Manual for details
Before tightening the suction manifold bolts (5), the four bolts (2) on the three cylinder blocks
must be well screwed in but not tightened, finally tighten them to torques indicated in Table VI with
torque wrench (see description below).
6.9.3. Discharge manifold
The discharge manifold (6) is fixed on each cylinder block with studs and nuts (8) and sealed
through O-rings. Before installation, thoroughly clean O-ring grooves in the cylinder block and sealing
surfaces on the discharge manifold; and the connection must be made up ‘metal to metal’, therefore, any
38
nicks, grooves or galling on the sealing surface must be repaired. Refer to the following section 5.10:
Welding and Repair, of this Manual for details.
Before tightening the discharge manifold nuts (8), the four nuts (8) on the three cylinder blocks
must be well screwed in but not tightened, finally tighten them to torques indicated in Table VI with
torque wrench (see description below).
6.9.4. Cylinder head flange
There are threads in cylinder head flange bore to facilitate removing of cylinder head, the flange
should be replaced if damaged. Before installation, thoroughly clean all burs, sharp edges or foreign
matters on the mating face, install the “leakage hole” of cylinder head flange downwards. To ensure its
end-face is perpendicular to the axial-line of the cylinder block, a ‘metal to metal’ connection on the
matching faces between the flange and cylinder must be made up. All nuts (10) must be tightened
evenly to the torque as shown in Table VI.
Table Ⅵ
Position Item No. in figure Torque, N.m
To frame 2 2170
Suction manifold 5 325
Discharge manifold 8 1355
Cylinder head flange 10 1840
The assembling of other parts of fluid end is shown as in Fig. 22, the assembling process is as
follows:
5 6 3 1
16
12
14 15
11 2
13 5
10
9
4
8 19
7
20 21 18
17
Fig. 22
39
6.9.5. Valve and valve seat
Remove the three valve pot covers（1）, three cylinder heads（2）and plugs（10）, thoroughly clean
all machining surfaces in fluid end with super solvent.
Make sure all valve seat bores are very clean and dry (free of dirt, grease, antirust etc.) and remove
all burrs or nicks with a fine emery paper, rubbing in a circular motion.
Thoroughly clean and dry the valve seat, install the suction and discharge valve seats into valve pot
bores, knock valve seats in place with copper rod or hammer, then install valve spring and other parts
properly.
Install mud baffle plate (11) at the end of extension rod.
6.9.6. Liner
Recheck liner bore and make it clean without sundries to make sure there is metal to metal contact
between liner and fluid end because sundries entering may cause liner to “turn up”, thus wearing in
advance to liner and piston may happen.
Coat liner bore of fluid end with grease or oil lightly, and then push the liner into the bore till their
contact face forms metal to metal contact.
6.9.7. Piston rod
Clean the piston rod and piston; make sure they are free of burs and nicks. Install the O seal ring
(20) into seal groove of piston and install piston on piston rod lightly and watching that the O seal ring
does not fall out of the groove. Tighten piston rod nut (21) to a torque 1200～1600ft.1bs（1625～
2165N.m）.
Coat liner ID and piston OD with grease; check and make sure the ends of piston rod and extension
rod are clean and free of burs and nicks. Insert piston rod into the liner and make piston rod centered at
the liner rear part. Drive the piston into the liner with a piece of hardwood or special tool. Be careful
that while the piston rod is approaching the extension rod you do not damage the aligning boss of the
piston rod end. The piston rod must be supported and guided into the aligning bore.
6.9.8. Piston rod clamp
The piston rod clamps are machined as one piece and then cut into two halves; and the two pieces
40
are stenciled with matching numbers and linked together with a chain. They must be used in pairs with
the same matching numbers. Clamp the end flange of the piston rod and tighten the clamping bolts to
torque 215N.m.
When the rods and clamps are new, there is a gap of more than 5.5mm between the two halves to
ensure the end faces of rods forming a good ‘metal-to–metal’ connection. As abrasion occurs, the two
halves will be pulled closer; if no gap exists, the clamps need to be replaced.
6.9.9. Lower valve guide and cylinder pusher
Install seal ring (5) at the rear of liner and assemble the liner to its proper position. Push cylinder
pusher (6) into the fluid end, make the lower bore of cylinder pusher aligned with lower valve pot bore,
and install guide (8) at the lower valve rod through the lower bore of cylinder pusher, rotate the vane of
the guide. Press the guide, press the spring (7) till the guide can rotate 1/4 circle, then make it into the
lower side of cylinder pusher. Install stop-motion clamp of lower valve guide (9) and clamp of turning
right (9) through the bore of lower valve guide to make the guide clamped on cylinder pusher and
locked. Sometimes you need to bend the middle of the clamp more or less to make the guide clamped
tightly.
6.9.10. Cylinder head
Install liner seal ring (5) into the bore of fluid end facing cylinder pusher, and install cylinder head
plug (10) into fluid end. Grease the matting thread of cylinder head (2), then install it on pump head and
tighten it with hammer and force-multiplier tool equipped with the pump.
If the fluid is leaking through the bleeder holes, it indicates that the seal are damaged or the
cylinder head is loose. Never block the bleeder hole. Once the cylinder head seal fails it will cause the
cylinder head threads and flange threads “washout” and damaged.
6.9.11. Valve pot cover
Install the valve pot cover seal ring (3) into the bore; coat the sealing parts and threads of the valve
pot cover with grease and then tighten the valve pot cover in place with the force-multiplier tool and
hammer.
6.10 Repair welding and repair

On occasion where washouts or normal wear of the fluid end bores need repair, the following
welding procedure and precautions should be strictly followed. Then all machined bore dimensions
41
should be in conformity with those shown in table Ⅴ, and in all cases ensure the shoulders (for
installing liners, covers etc) 90° to the axis of the bore.
6.10.1 Welding procedures
Weld repair to washout damage and crack damage are different, outlined below is the basic
information for the repairs:
A. For washout
（1）weld as 30# carbon steel.
（2）Before welding, clean area to be welded by grinding or carbon-arc-air-gouging, the welding
rod should be dry and free of moisture, if necessary, put them in an oven to dry.
（3）Heat the welding area to 250°F～ 350°F（120°C～180°C）, out in all direction for a minimum
of 3″（75mm）
（4）Use AWS-ASTM E-60-7018 low-hydrogen welding rod, such as Adam-Arc7018.
（5）The temperature should be dropped to 250°F～ 350°F（120°C～180°C）after each pass and
maintained throughout the welding. After welding repair is completed and area cleaned, heat it again to
250°F～ 350°F（120°C～180°C）, and then allow cooling down slowly.
B. Cracks
（1）Grind out all of crack. Any attempt to torch cut out a crack will result in the crack progressing
faster than the material can be cut.
（2）Preheating: The purpose of preheating is to expand the welding area so that when cooling, the
welded area and the preheated area will cool more uniformly, thus to avoid ‘thermal cracking’ and
prevent the ‘hard spot’ forming between the base metal and the ‘welding metal’; These hard spots are
just the places where fatigue crack will start.
Follow the same welding procedure as above for washout repair
6.10.2 Repairs to valve pot cover bore
When making repairs to washouts in the valve pot cover bore, it is extremely important that the
surface where the valve cover seats is either turned or bored perfectly flat and 90° to the axis of the
thread. As shown in Fig.23, the valve pot cover seal（1）seats in the counterbore at top of valve pot
deck, and as the cover makes up metal to metal to the valve deck, the seal ring was sealed in the lower
point machined by turning or boring, otherwise, a gap will be formed between the end faces of valve pot
cover and valve pot deck, through which the seal ring will be extruded and damaged under pressure.
42
Any high or low spots could also cause the valve pot cover to become ‘warped’ and result in severe
damage to the threads.
Fig. 23
6.11 Replacing air bladder of dampener

Replacing the air bladder of dampener according to following steps（see Fig. for KB-75 dampener
assembly）:
1) Make sure the pressure in the system is completely released. (See the above-mentioned)
2) Remove the cover (5), which can be jacked out by two thread holes; if a stud was rotated out
from the shell while removing, first remove the nut (R2), and then clean the bolt and thread hole, rotate
again the stud into the hole (with special stud spanner or putting two nuts together tightly with common
spanner) and finally tighten them to torque 670 ft..lbs（910 N·m）
3) Take out the air bladder. Insert a rod between the shell and bladder and press the bladder and
take it out from the top.
4) Check the condition of the bladder, good or broken, if damaged, inspect any convexity or
foreign objects in the related place, and eliminate all factors caused the damage.
5) Check the condition of the bottom plug and all edges must be smoothed. It must be replaced if
damaged by wear or punctured, install it vertically and with a interference of 0.003"～0.006"（0.076～
0.152 mm）
6) Install the new bladder
Roll and coil the bladder as a spiral-shaped until it can be put in from the upper opening and then
43
stretch and adjust the bladder to make it fit closely with the shell, finally push the seal neck (shoulder)
to shell opening and coat the inner side of neck with greases.
7) Install the cover（5）and be careful not to extrude or deform the bladder.
8) Tighten the nut（R2）to torque 1200～1600 ft.lbs (1625～2165N.m ).
9) Inflate the dampener according to item 4.5.5 described.
7 Information in Maintenance Work

In order to keep drilling pump running free of trouble and with a longer service life, correctly
doing maintenance work duly is very important, to every drilling pump, we must emphasize periodical
maintenance.
7.1 Daily maintenance work

1 Check the oil level of power end when stop running, check the oil level of chain drive box if
chain drive is adopted.
2 Inspect the working condition of liner and piston, a few mud leakage is allowable for it doesn’t
mean liner and piston fail. If the mud leakage excesses normal limit, the liner and piston should be
replaced.
3 Inspect the liner chamber of mud pump frame, clean it if there are much mud sediment.
4 Inspect whether there is sufficient water in water tank for spray pump or not, whether the cooling
water is polluted or not, supplement water or change water and clean water tank in time if necessary.
5 Check the charging pressure of discharge dampener.
6 Inspect the reliability of the shear relief valve.
7 Loose the piston rod clamp, hand turn the piston for a quarter turn, tighten clamp again. This can
make the piston to wear evenly and extend the service life of piston and liner.
8 Coat the threads of valve pot cover and cylinder head with grease before tightening, check them
every 4 hours for looseness.
7.2 Weekly maintenance work

1 Remove the valve pot cover and cylinder head, clean them thoroughly, coat with MOS2
compound calcium base grease, check the inner bushing of valve guide for abrasion, replace it if the
clearance between valve stem and bushing excesses 0.11″（3mm）.
2 Check the condition of valve and valve seat, replace them in pair if they are badly worn or
washout.
3 Check the piston locknut, replace if necessary (replace those locknut for unscrewing and
44
tightening more than 3 times)

4 Drain water from the plug on drainage cover until oil appears.
7.3 Monthly maintenance work

1 Check all nuts and studs, such as the nuts for cylinder thread ring fixing, the connection nuts for
fluid end and frame, and the connection bolts and nuts for suction manifold and discharge manifold etc.
Tighten them according to stipulated torque if necessary.
2 Check the sealing ring in packing box for extension rod, replace if necessary. Replace them every
3 months at least. Note the seal orientation during replacement.(see figure 24)
1 crosshead 2 single lip seal 3 double lip seal 4 extension rod
Fig. 24
3 Disassemble and clean the strainer of discharge filter, then reassemble them.
4 Every 6 months, replace all lubrication oil in crosshead groove and power end sump, and clean
them thoroughly.
7.4 Yearly maintenance

1 Inspect the crosshead guide for tightness, check whether the clearance is in the range as required,
add shims under guide to adjust the clearance if necessary. Turn the crosshead 1800 while disassembling
and reassembling the crankshaft assembly.
2 Recommend to overhaul the drilling pump every 2-3 years, inspect the main bearing, eccentric
(crank) bearing, crosshead bearing, pinion shaft bearing for wear and damage, replace if necessary
3 Inspect gear for wear, if the wear is severe, the crankshaft and pinion shaft should be reinstalled
by changing their direction simultaneously to use the unworn gear surface
45
7.5 Other precautions in maintenance

1 The 25°taper surface on clamps of extension rod and piston rod must be cleaned before assembly
2 Replace liner together with its seal ring
3 If the mud pump is shut down in winter, the mud in valve pot and liner must be drained out.
4 All inspection holes shall be covered well to prevent dust entering the lubricate oil.
5 The discharge dampener must be inflated with inertia gas like nitrogen only, no explosive gas
such as oxygen and hydrogen permitted.
8 Possible Failures and Troubleshooting
8.1 Fluid end

Failure Possible causes Troubleshooting
1 Mud pressure drop, less 1、 bad seal of suction

1、 tighten the suction flange or
mud discharge or no mud manifold, air entering
replace gasket
discharge 2、 suction strainer
2、 clean sundries in strainer
blocked
1. A piston or valve have 1. replace the damaged piston, open
2 Mud discharge unevenly, been worn or damaged the valve pot cover to check
pressure fluctuate badly, whether the valve is blocked or not
2. Air entering
noise in suction manifold 2. check the suction manifold and
cylinder head for tightness
1. piston locknut loose
1、 tighten the piston locknut.
2. liner lock loose 2、 tighten the liner lock
3 Knock sound in liner
3. bad suction, water 3、 eliminate the factor result in
hammer bad suction
4 Mud leaks from valve 1、 valve pot cover and 1、 tighten valve pot cover and
pot cover, cylinder head cylinder head loose cylinder head
seal bore 2、 liner seal damaged 2、 replace liner seal
1、 inflating fitting
5 Discharge dampener can 1、 clean sundries in inflating
blocked
not be inflated or inflated fitting
2、 air bladder broken
gas leaks quickly 2、 replace air bladder
3、 needle valve with bad
3、 repair or replace needle valve
performance
1. discharge filter (strainer) 1. Disassemble filter, remove
6 Diesel engine overload
blocked sundries and clean filter
46
8.2 Power end
Failure Possible causes Troubleshooting
1. oil line or oil hole blocked

1 Motion friction parts 2. lubrication oil too dirty or
1、 clean oil line and oil holes
such as bearings of deteriorated
2、 replace lubrication oil
power end, crosshead 3、 rolling bearing worn or
3、 check or replace bearing
etc. overheat damaged
4、 make lube oil proper
4、 Lube oil too much or too
less
1. adjust clearance or replace
1. crosshead guide worn worn crosshead guide
2 Abnormal noise with 2. bearing worn 2. replace worn bearing
bearings, crosshead etc. 3. Guide loosen 3. tighten the screws for guide
4. water hammer at fluid end 4. improve mud pump’s suction
performance
9 Attentions in Preservation
1 If the mud pump is not operated for a long period, it should be mothballed properly.
2 Do thoroughly cleaning and drain the fluid end completely before preservation, clean them with
clear water and dry.
3 Drain the lubrication oil in oil sump of power end and remove all sediment.
4 Coat all bearings, crosshead, gear, piston rod, crosshead extension rod with thick oil.
5 Coat all machining surfaces of components of fluid end with grease.
6 Cover the suction and discharge ports with blind flange
7 Close all inspection windows and other openings tightly
10 Attentions in ordering
A single drilling pump package includes following while delivery:
1 Main body part: drilling pump assembly, spray pump assembly, discharge dampener assembly,
shear relief valve etc. The big pulley (driven pulley) / coupler and master skid are not included
2 One set of rubber seal for replacement once, and one set of special tool for disassembling and
assembling are supplied along with drilling pump package delivery
3 Without special requirements of customer, a set of 6 3/4” mono-metal liner and piston is installed
while leaving factory; the spray pump is driven by pinion shaft; the lubrication pump is arranged with
“built-in” mode. If you have different requirements, inform us in written while ordering.
47
11 Special tools list delivered with HHF-1000 drilling pump

No. Drawing code. Name Qty.
1 GH3101-25.01 Sleeve 2″ 1
2 GH3101-25.02 Sleeve2 3/16″ 1
3 GH3101-25.03 Sleeve2 3/8″ 1
4 GH3101-25.04 Sleeve3 3/8″ 1
5 GH3101-25.05 Joint 1″ 1
6 GH3101-25.06 Extension rod 8″ 1
7 GH3101-25.07 Extension rod 24″ 1
8 GH3101-25.08.00 Disassembling tool for cylinder head plug 1
9 GH3101-25.09.00 Assembling tool for valve rod guide 1
10 GH3101-25.10.00 Disassembling tool for cylinder pusher 1
11 GH3101-25.11.00 Hydraulic valve puller 1
12 GH3101-25.12 Transitional taper sleeve 1
13 GH3101-25.13 Pressing sleeve 1
14 Manual oil pump（63MPa） 1
15 Inner hex. spanner 5/8″ 1
16 GH3101-25.14 Sleeve 1 1/2″ 1
17 GH3101-25.15 Sleeve1 5/8″ 1
18 GH3101-25.16.00 Long sleeve 1 5/16″ 1
19 NB800M.25.09.00 Cylinder head rod 1
20 NB800M.25.03 Sleeve 1 13/16″ 1
Note: When discharge 5-w joint assy. is adopted, No.20 sleeve 1 13/16″ shall be used.
48
12 Spare parts list delivered with HHF-1000 drilling pump

1 GB/T3452.1-1992 O RING 97.5×3.55G 3
2 GB/T3452.1-1992 O RING 175×3.55G 3
3 GB/T3452.1-1992 O RING 115×5.30G 3
4 GB/T3452.1-1992 O RING 140×7.0G 3
5 GB/T3452.1-1992 O RING 165×7.0G 1
6 GB/T3452.1-1992 O RING 190×7.0G 3
7 GB/T3452.1-1992 O RING 345×7.0G 3
8 GH3101-03.11 Oil seal 8.5″×10.5″×0.625″ 2
9 GH3101-04.06 Oil seal ring 3
10 GH3101-04.18 Double-lip oil seal 4.5″×5.5″×0.5″ 6
11 GH3101-05.04 Liner seal ring 6
12 GH3101-05.09 Valve cap seal ring 3
13 GH3101-05.17.05 Valve rubber 6
14 GH3101-05.19.07.02.00A Piston rubber 6 3/4 3
15 GH3101-05.20 Piston seal ring 3
16 GH3101-05.29.01 Rubber bladder（suction dampener） 1
17 GH3101-09 Seal washer 2
18 GH3161-22.04C Gasket ring R35 2
19 GH3161-22.06 Gasket ring R27 2
20 GH3101-23 Gasket ring R44 3
21 GH3101-27.01 Gasket ring R39 1
22 GH3101-27.03.00 Air bladder（discharge dampener） 1
23 GH3101-28.03.00 Piston assy.（safety valve） 1
24 GH3101-28.06 Buffer pad（safety valve） 1
25 GH3101-28.11 Shear pin（safety valve） 10
Note: 1. When discharge 5-w joint assy. is adopted, No. 18 gasket ring R35 shall be used: when
discharge elbow assy. is adopted, No. 19 gasket ring R27 shall be used.
2. If shear pins are not used for HP safety valve, No. 23, 24, 25 parts may not be used.
49
13 Recommended spare parts list (HHF-1000 drilling pump)

1 GB/T3452.1-1992 O RING 97.5×3.55G 6
2 GB/T3452.1-1992 O RING 175×3.55G 6
3 GB/T3452.1-1992 O RING 115×5.30G 6
4 GB/T3452.1-1992 O RING 140×7.0G 6
5 GB/T3452.1-1992 O RING 165×7.0G 2
6 GB/T3452.1-1992 O RING 190×7.0G 6
7 GB/T3452.1-1992 O RING 345×7.0G 6
8 GH3101-03.11 Oil seal 8.5″×10.5″×0.625″ 2
9 GH3101-04.06 Oil seal ring 3
10 GH3101-04.9 Extension rod 3
11 GH3101-04.18 Double-lip oil seal 4.5″×5.5″×0.5″ 6
12 GH3101-05.04 Liner seal ring 12
13 GH3101-05.09 Valve cap seal ring 6
14 GH3101-05.16 Valve spring 6
15 GH3101-05.17.00 API 6# valve assy. 24
16 GH3101-05.17.05 Valve rubber 24
17 GH3101-05.18.00 Piston nut 6
18 GH3101-05.19.02.00A Piston 5 3
19 GH3101-05.19.02.02.00A Rubber 6
20 GH3101-05.19.03.00A Piston 5 1/2 3
21 GH3101-05.19.03.02.00A Rubber 6
22 GH3101-05.19.04.00A Piston 6 3
23 GH3101-05.19.04.02.00A Rubber 6
24 GH3101-05.19.05.00A Piston 6 1/4 3
25 GH3101-05.19.05.02.00A Rubber 6
26 GH3101-05.19.06.00A Piston 6 1/2 3
27 GH3101-05.19.06.02.00A Rubber 6
28 GH3101-05.20 Piston seal ring 6
29 GH3101-05.21 Piston rod 3
30 GH3101-05.22 Bi-metal liner 5 3
50
31 GH3101-05.22 Bi-metal liner 5 1/2 3

32 GH3101-05.22 Bi-metal liner 6 3
33 GH3101-05.22 Bi-metal liner 6 1/4 3
34 GH3101-05.22A Normal liner 6 3/4 3
35 GH3101-05.29.01 Bladder（suction dampener） 1
36 GH3101-27.03.00 Air bladder（discharge dampener） 1
37 GH3101-28.03.00 Piston assy.（safety valve） 5
38 GH3101-28.06 Buffer pad（safety valve） 5
39 GH3101-28.11 Shear pin（safety valve） 10
Note:
1) On HHF-1000 drilling pump delivery, there are 3 pcs of 6 3/4 mono-metal liner piston in the
package.
2) If shear pins are not used for HP safety valve, No. 37, 38, 39 parts may not be used.
3) This list is the quantity needed for one pump.
Translated by ： Date:
Proofread by： Date:
Finalized by： Date:
51

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HHF-1000 DRILLING PUMP

4 Use of new pump ................................................................................................................................7

6 Maintenance and Assembling of Main Components.....................................................................25

7 Information in Maintenance Work.................................................................................................44

8 Possible Failures and Troubleshooting ...........................................................................................46

9 Attentions in Preservation ...............................................................................................................47

3 Technical Specifications and Parameters

3.1 Technical specifications

TableⅠ Technical specifications for pump HHF—1000

No. Model HHF-1000

3 Rated stroke number 140SPM

4 Length of stroke 10″（254mm）

5 Gear type Herringbone tooth

6 Gear ratio 4.207:1

7 Connection size of suction port 12″ flange（about 305mm）

8 Connection size of discharge port 5 1/8″flange 5000psi API（130mm flange 35MPa）

11 Size of valve pot API 6#

160″×124 5/8″×71 9/16″

13 Skid length×width 160″×70 1/2″（4063×1790）

14 Weight of main body 18910kg

1.frame assy. 2.crankshaft assy. 3.pinion assy.

3.2 Performance parameters

3.3 Overall dimensions

4 Use of new pump

4.1 Installation of new pump

4.1.1 Requirement to foundation

4.1.2 Ground installation

4.1.3 Fixing installation

1 pump skid 2 shims 3 T-beam 4 deck

4.1.4 Installation of drive device

Tightening Force exerted on

4.1.4.1 V-belt drive

A. Checking sheave groove status

B. Checking sheaves alignment

C. Adjustment of V-belt pre-tension

center distance is 150” (3810mm), a 3/4” (19mm) distance is to be increased.

4.1.4.2 Chain drive

B. Lubrication of drive chain

Ambient temperature above 0°C（32°F） SAE-30/N100

Ambient temperature below 0°C（32°F） SAE-20/N68

When ambient temperature below -18°C

—— Daily check oil level;

—— Daily check oil condition;

—— Daily check oil pressure, 5～15psi（0.035～0.103MPa）;

—— Check oil amount supplied to chains;

—— Check nozzle condition on spray tube;

—— Check the working condition of oil pump drive（V-belt or chain）.

4.2 Requirement to suction system

4.3 Preparation of power end

4.3.1 Power end lubrication

3) Install the “O” ring（8）into groove of stuffing box。

5) Install the retainer spring（9）.

4.4 Spray pump system

1.to spray pump suction pipe

4.5 Checkup in fluid end

4.5.1 Valve and seat

4.5.2 Liner and piston

4.5.3 Suction flange

4.5.4 Discharge manifold

4.5.5 Assistant manifold

3 Open the shutoff valve on dampener

6 Close the shutoff valve on dampener.

5.1 Minimum operating speed

5.2 Flow-controlled splash lubrication system