HHEF-1300/1600 Mud Pump Ah, mm AF CHANUOU GUANGHAN HONGHUA CO., LTD Issue Date: September 2005 Printed in CHINA10 u 2 B 4 1s CONTENTS Introduction «sees eer eee Pe Technical specification and performance parameters ....s-eetene secesnescesn Installation of new pump. : a 16 Requirements for suction system u Preparation of power end ‘Spray pump assembly Assembly of fluid end parts ‘ ceseneseerseesee 1B Lubrication : 223 Maintenance ... 29 Daily maintenances of Pump ... Ercheneonoersteeer Possible failures and how to eliminate them, 51 Altentions for mothballs.. a 252 Special Tools List For HHF-1300 / 1600 Mud Pump, delivered together with the pump.....52 Spare Parts Lift For HHF—1300 / 1600 Mud Pump, delivered together with the pump..... 53 Recommended spare pars .x USER MANUAL OF HHE-1300600 MUD PUMP USER MANUAL OF HHF-1300/1600 MUD PUMP 1 Introduction HEF-1300/1600 Mud Pumps are horizontal, triplex single acting reciprocating pumps. It feeds high-pressure circulated drilling fluid to bottom hole, which flushes the bore-hole bottom and crushes rocks; furthermore, cools and lubricates drill- bits and carries the euttings (rock chips) to the surface ‘The Pump mainly consists of two components, power and fluid ends. The power end includes the assemblies of frame, pinion shaft, crankshaft, crossheads etc. The fluid end includes the assemblies of hydraulic eylinder, valves, eylinder liner, piston, suetion and discharge manifolds and so on, Itis designed and manufactured that all parts and components of the pump conform with the requirements specified by the “Specification for Drilling and Well Servicing Equipment” (API Spec 7K). All easily worn parts at the fluid end such as cylinder liner, piston and valve assemblies etc are universal and interchangeable and could be replaced with the same type parts and components in conformity to the above-said API Specification. To avoid ‘air hammer’ and reduce outlet pressure fluctuation, a suction stabilizer and discharge pulsation dampener were respectively installed at the suction pipes and one side of pump ontlet, At the other side of pump outlet, areset safety valve is installed to guarantee that the pump pressure would not excess the rated working pressure. Bach ‘mud pump is equipped with a charging pump to ensure good suction performances for the pump while operating at high strokes. A combination of splash and forced lubrication systems has been used to Iubricate all gears, bearings and crossheads in the power end. The cylinder liners and pistons in the fluid end will be lubricated, cleaned and cooted by water supplied from a spray pump. For conveniences of daily maintenance, a set of apecial removers/tools will be delivered together vwith the pump. Except for differences in the gears and bearings at the power end of the pumps., Frame, fluid end and so on for pump HHF-—~1300 are the same as pump HHF-—~1600. For convenience of users" understanding and use, the two pumps are introduced simultaneously in the following texts.» = USER MANUAL OF BHE-1300/1600 MUD PUMP. 2 Technical specification and performance parameters 21 Technical specifications: ‘The Technical specifications for pump HHF—1300/1600 are shown in the following table 1: Toble T ‘Technical specifications for pump HHF—~1300/1600 No Model HHF-1300 HEF-1600 1 | type Horizontal, single ating, triplex piston 2 | Input power rated 100mp ( 969%W) 1600hp (193K) 3 | Maximum eylinde liner diameter 7 (718mm) 4 | Lenatnof stroke 12" (304mm) 5 | Rated numberof stroke 120sPM 6 | typeof gears Herringbone tooth 7 | Gear tatio 4.206 8 | Dimensions of valve pot APL 7 9 | Ween 25850ke 2610045dh, zt USER MANUAL OF HHF-1300/1600 MUD PUMP_ 2.2 Performance parameters ‘The performance parameters for pump HHF—1300/1600 are shown in the following table I: Table I Performance parameters for pump HHF—1300/1600 Diameter of eylinder liner and vated pressure Stoke ‘yim | 63/417imm | 6:12 165mm | 6° 152mm | S12 MOmen |$° 127mm numbers HHF-1300 2nsie2 | ae 206 | 3230 222 | sym261 | asv7 sia | somosas psi Mra | psi MPa | psi MPo | pst MPa | poi MPa} pi MPa vans | wom | sonme | warn | seus | was st. 100 sow ws naa [nat mee | aa mee | at me | ot are | pe ad pore Discs sunrise | ue-c00 uosip [ a7stp | raoorm | asenm | oom | sam | wicew | scr isa 10a9kW | 1292KW | 49.19L/S | 45.74LIS | 4241 LIS | 36.14L/S | 30.37L/S | 25.10 LIS waonip | teip | rzvae | corcen | carom | saver | saan | soon ae 969 kW 193kW | 4541S | 4222S | 39.1SLS | 33.36L/S | 2803S | 2317S uiatip | iaééap | soon | osc | soar | assorm | sorone | savcrm ae 838 kW WON KW | 41.62L/S | 3870LIS | 35.89L/S | 3058L/S | 28.70LIS | 2124L/S wassip | assay | coor | asec | sivama | soars | azocnw | soca oe 807 KW g92KW | 37.B4L/S | 35.18L/S | 3263L/S | 27.80L/S | 2336LS | 1931 US sisip | t2o0ip | swoon | soacre | sssorm | oom | sncem | asco ‘ 726 KW gso3kw | 3405LS | 3167L/S | 29.36US | 25.02LIS | 21.02L/S | 1737L/S serip | oeste | ssocmm | aocmw | siscew | ssoom | sear | usaw i 646 KW W94kW | 3027US | 2BISLIS | 26.10LS | 22.24L/S | 1869L/S | 15.44 L/S Tstie | saip | evan | s9ocem | seacrn | aceone | avon | aia in 565 KW o9skw | 2649LIS | 24.63LIS | 2284L/S | 1946L/S | 1635L/3 | 1351LS soar | sssar | sive | saoce | aoc | sesame i 037848 | 0.3518 L/S | 0.3263 L/S | 0.2780L/S | 0.2336 LIS | 0.1931L/S Note: a, calculated as per volumettic efficiency (100%) and mechanical efficiency (90%) b. Shows rated stroke numbers while operatinghy an USER MANUAL OF HHF-}300/!1600 MUD PUMP 2.3 Overall dimensions ‘The overall dimensions for pamp HHF—1300/1600 are shown in the figure 1: 1723, as 4 1466 1261 Figure 1BY umueenneenuore 3 Installation of new pump ‘The nud pump HHF-1300/1600, manufactured by our company, has been completely assembled and test-operated under full load and then discharged all lube oils from power end before being delivered to our customers. The pump must be checked and operated according fo the following methods and measures before being put into formal services. In onder to prevent personal injury during the performance of any checking and maintenance processes, it must be shut down and not, operating, all safety and protection facilities installed on the prime mover and drive device should be put in safe positions. 34 Setting of pump ‘The skid under the HHIF-1300/1600 pumps 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 lower resistances against twist; therefore, the supports under the frame must bbe level and with enough strength to bear the pump’s dead load and dynamic forces exerted upon during operation, 3.2 Land installation In land installation, itis suggested that a mat base with, atleast, eight pieces of 37 * 12” (76mm * 30Smm ) boards be placed under the pump skids along the entire length» the positions as shown in the Figure 2. The board 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.ze USER MANUAL OF HHF.1300/1600 MUD PUMP Figure 2 3.3 Permanent installations ‘While the pump being permanently installed on the structural base or concrete slab on a barge or drilling platform and the pump skid being fixed by bolts, it is essential that the skid be properly shimmed to prevent the power fiame from possible distortion or twists. The pump skid rmust be solidly sat down on all shims when all bolts are tightened. In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installing shims are shown in the Figure 2 and 3. Properly shimming should be noted 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” (305inm). ‘When integral installations for power unit or electric motor and pump skids are required, the pump must be fixed on the skids of the T beam, with retention blocks rather than bolt 3 in this ‘way, the pump could be abit “floating” so as to reduce greatly the possible deformation of the pump frame caused by the deformation of barge deck or platform,th a* USER MANUAL OF HHF-1300/1600 MUD PUMP LLL | Pa a Shin gs Tobeam Dec, SAAS Ss 3.3. Installation of drive ‘Whether to use V- belt or multi-strand chain or universal shaft for the drive between power source and the pump, it must be very careful during the whole installation to ensure the longest service life and minimize the shut- downs caused by failures from the drive. ‘Upon installation of drive sheave or sprocket, make sure all ust preventatives or greases in the hub and on the shaft are removed; 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 elements. The shaft of the pinion gear should be coated with light lube oif or anti-seize 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 exceeding torque, therefore, it is imperative to adhere to 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 must be tightened alternately and gradually. Pump model Hub Wrench torque | Wrench Length | Fores exerted on wrench oot .bs 36" 200 ibs BHE-1300/600 w 813Nm 900mm. 900N 3.4.1 Vebelt drivedh, xe USER MANUAL OF HHF-1300/1600 MUD PUMP 3.4.1.1 Checking sheave groove status Before installation, check that the sheave grooved are not worn out and getting rounded, otherwise, the Vebelt will be damaged quickly. The groove sidewall must be level and straight and there are no dusts, rusts. 3.4.1.2 Checking sheave alignment Having installed all sheaves and tightened them to working status check their alignment. If the distances from one side of the two sheaves to the centerline of sheave groove are equel, check the alignment with two tightened strings (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 of the sheave rim; in this way determining the ‘wo centerlines of the drive sheaves are parallel and their side face be vertical with their axle line. 3.4.1.3 adjustment of V-belt pretension force To adjust the belt tension, change/increase the central distance between two sheaves until no sag to bbe found on the tightening belt side, and the slack side is also tightened but has a bit of sags. And then increase a certain of central distance again, for example, if the center distance is 100" (2540mm), 1/2” (13mm) is fo be increased! after completion of adjustment of the central distances again ifthe center distance is 150” (3810mm), 3/4” (19mm) is to be increased. Note: Don't obtain belt tension by lifting the pump or by lowing the pump below ground level to allow the bel! to be tensioned by pump’s weight. 3.4.2 Chain drive Installation and maintenances correctly 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 exactly as possible, As mentioned above in 3.4.1.2, 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; in this way, to determinefh ae USER MANUAL OF HHF-1300/1600 MUD PUMP the two centorlines of sprockets are parallel and their end face be vertical with their axle line. 3.4.2. Lubrication of chain drive ‘Tho Inbrication system used for all chein drive in HH series pumps isan independent one, which has its own lube il pump, reservoir and drive, Filling the lube oil into the chain case must be up to the indicated height. The lube ol to be used areas follows: Ambien temperature above 32F (0° C) — SAB-30/N100 Ambient temperature below 32F (0°) SAE-20/N68 If Ambient temperature below 0° F (-18° C) , Please consult a reputable Tube oil dealer for recommendations. As for those approved hube-oil specifications and their supplements, references might be made to the teports/bulletins usually used on hibe ofl, which are written and published by cilemannfacturet, If there is any diserepaney between manual and the reports/bulletins, the suggestion from the reports/bulletins shall be prevailed. E Owing to the chain lube system being an independent system, the maintenance must be carried out ‘based on equipments special requirements, which include Daily checking oil level Daily checking oil status M Daily checking oil pressure ( (5~ 1Spsi) ( 0.035 ~0.103MPa ) Supplying some oils to chain Checking nozzle’s working status on the spray tube Checking the working conditions ofthe oil pump's drive (Wbelts, or chain) Note 1. There is a pressure relief adjusting screw on the rear of the pump housing to adjust the off pressure ’, When oil pressure is too high or too low, which indicate that the suction and discharge filter soreens need cleaning. 4 Requirements for suction system ‘The design of pump suction system has been considered to install the system independently. To obtain a satisfied suction performance, the HHF series pumps must have positive head (pressure);dh Sia ceiat USER MANUAL OF HHF-1300/1600 MUD PUMP the optimurn pressure for suction manifold is 20~30psi_ (0.14~0.21Mpa) . Under this pressure, the pump could have the maximum volumetric efficiency and the longest service life for consumable parts. ‘This pressure can be obtained by 5 * 6 charging pump with a 40 hp, 1150-rpm electric motor, A special kind of device is necessary to keep the charging pump and the triplex pump automatically and synchronously tured on and off. For drilling rigs driven by DC motor, usually a signal seneling out from DC contro! panel actuates the electromagnetic starter; at this time, the air line of drilling pump clutch can provide a group of contactors when clutch is engaged, through which supply power to the electromagnetic starter: ‘The suction pipeline should be aranged with a by pass for the charging pump, to facilitate the illing pump’s continuous operation wien the charging pump is in maintenance or failure. When the chilling pump is operated without charging pump, usually replace a softer suction valve spring 10 improve suction performances. Suction stabilizer is a very efficient supplementary device, which can fully charge the fluid into cylinder liner and greatly eliminate the fluid fluctuations in suction pipes resulting in a smoother flow inthe discharge line. Note: Don’t connect the discharge pipe of the safety valve to the suction pipeline, since when the safety valve opens it causes a sudden rise to the system internal pressures if the pressure is higher than the rated pressure of the system, it will damage the manifold, suction stabilizer and centrifugal pump ete, 5 Preparation of power end Before being shipped to the users, the HHF series pump manufactured by our company has been completely assembled and test operated, All lube oils have been drained, Before operating the pump, the following operations and checks must be carried out. 5.1 Power end lubrication Before filling lubricant, open inspection window on cover and check power end oil reservoir for possible accumulation of condensation, and drain and fh th the inner chamber by removing the pipe plugs on each side of the pump (sce item 2, Fig.7). Fill in the proper brand and quantity of Junbrication oil in the power end according to the requirements specified on the designation plate ofoh ae USER MANUAL OF HF-1300/1600 MUD PUMP pump frarne Recheck oil level after pump has operated for a period of 15 minutes, Shut pump down for about $ minutes until oil stabilized, check oil level gauge (see item 1, Figure 7). Itis usually necessary for a few more gallons (10 liters) of oil to be added due to a certain amount being retained in the crosshead and frame cavities. 5.2 Installation and inspection of Crosshead Extension Rods and Diaphragm Stuffing Box Seals for HHF-1300/1600 Pump ‘As shown in Figure 4, remove the diaphragm stuffing box and splash- guard (1) and rotate pump so that crosshead is at the front of the stroke, check bolttightening status. If the cleanliness of front part of crosshead and its extension rod and bolt- tightening are not up to the requirements, remove the extension rod and thoroughily clean the crosshead front and the end face of the extension rod; and then insert alignment boss on crosshead extension rod outer circle into the crosshead bore and install the bolts (2) to the torque: 350 ~ 370 Fu.lbs, (475 ~ 500N.M), finally lock it with steel wire, Figure 4 Upon assembly, clean the mating face between splash-guard and frame as shown ‘A’ in Figureze USER MANUAL OF HHP-1300/1600 MUD PUMP. 4, and then fix the seal (3) and bolt (10), the bolttightening torque is 90 ~ 1208. Ibs (120~ 160N.W). Clean inner bore and end face of splash-guard, and clean the outside surface and flange face of the iaphragm stuffing box; coat the outside surface of the diaphragm stuffing box with light ofl and install O-ting seal (4); and then insert the diaphragm stuffing box to the splash-guard and finally install the seal washers and end covers sequentially. Be careful that the backflow hole of the diaphragm stuffing box and the drainage hole of the end cover must be positioned downvvards,Tighten bolts up to the torque: 12 ~ 18ft.Ibs (16 - 24NM) ‘The diaphragm stuffing box assembly has two double tip oil seal (6), oil seal ring (7), “O”- zing. (42), O-ring (8) and lock spring (9) etc. Install the assembly as follows: a, Remove the spring (5) from the double lip oil seat (6) and place the seal on the outside of the orosshead extension rod, but main lip towards power end. Install spring’(S) on the oil seal lip, and then slide the seal into the diaphragm stuffing box. (See the following note), b. Install the O-ring (12) into oil seal 1 (7), put (7) and (12) together over the extension rod and then slide it into the stuffing box bore. ©. Install the O-ring (8) into the groove of the stuffing box. 4. Install the double lip oi seal at right side (6) in Figure 4, the method is the same as a. Note: The double lip oil seal (6), near to the power end, can be replaced by single lip oil seal, but the outer one (hydraulic end) cd not, e. Install lock spring (9), its opening must be just downwards. Note: Caution must be taken to assure the pressure spring (5) will not slip out of groove of the oil seal lip when the extension rod is heavily scored. The extension rod must be coated with light oil, which facilitates installation of all parts in the stuffing box assembly. 6 Spray pump assembly The spray pump assenibly consists of spray pump, water tank and spray pipe with nozzles ete, The function of spray pump is to supply water in the form of spray to the cylinder liner and piston to lush, lubricate and coo] them to extend the service life of the eylinder liner and piston.ze USER MANUAL OF HHF-13001600 MUD PUMP ‘The spray pump is a centrifugal pamp, which is electric motor driven and uses water as cooling and Iubrication fluid, Attention must be paid to assure the cooling fluid is supplied to the cylinder liner and piston, otherwise immediate damage of piston rubber parts and cylinder liner witl oceut. ‘The HEE series mud-pumps manufactured by our company use a stationary spray pipe, as shown in Figure 5, which consists of a fixture (1), connecting pipe (2) and spray nozzle pipe (3). It sprays the cooling fluid to inner holes of cylinder liner and piston, The spray nozzle pipe should be checked often as the pump works. Through adjustment of water supply to the manifold, to assure enough cooling fluid to be sprayed directly to piston, Figure $ Cooling fluid will be transfused by pump (jtem3, Figure 7), and sucked from water tank (jtem 5, Fig.7), to the manifold located in the left (right) wall plate of the frame. By regulating the ball valve (item 4, Fig.7), the pump will supply water to the inside of the cylinder liner without splashing back on the crosshead extension rod, Water should not splash on the extension rod otherwise some of water will spray into the power end contaminating the lube oil. ‘The cooling fuid is retummed from frame drainage hole to water tank’s setting chamber, and as the fluid flows through the filter screen, the solids settle as shown in Fig. 6.dh =e USER MANUAL OF HHF-1300/1600 MUD PUMP Its important to check condition of the cooling fluid at frequent intervals and clean and flush the water tank as well as replace the cooting fluid as required, otherwise the contaminated fluid will ccause early wear of liner and piston or block the spray nozzle pipe, a filee eoreen settiog ensaber azsia as C. | to spray pump Figure 6USER MANUAL OF HHE-1300/1600 MUD PUMP &a xe USER MANUAL OF HI5R-1300/1600 MUD PUMP 7 Assembly of fluid end parts ‘The cross-section of the fluid end is shown in Figure 8, clean and install all parts of the fluid end ‘must follow the methods as follows. Note: The parts in the fluid end are designed for ‘metal to metal’ installations to reduce wear caused by high-pressure fluid which is usedl in modern high-pressure-pump operations. Based on this consideration, in order to ensure @ reliable sealing between parts in the fluid end, it is required to clean all parts thoroughly and have no burs, scores or rusty spots ete 7.1 Valves and seats Remove all three valves pot cover (18), thee cylinder heads (16) and plugs (15), ond thoroughly clean all machined surfaces in the aid end! with a good cleaning solvent. Make sure all valve seat bores are very clean and dry (free of dirt, grease, anti-ust additives ete.) and remove all burs and nicks with a fine emery cloth. Clean and dry thoroughly the valve seats and install suction and discharge valve seats into the valve cavity bores and then install the valve body; knock the upper part of the guidepost with a copper hammer to drive the valve seats in place, finally install valve springs and other part. 7.2 Cylinder liner Insert liner- seal- rings (1) into the counter-bore of the cylinder. Install the wear plate (2) in place with stud bolt, and then install liner flange (3), be sure that the liner lock starting point is at the 5 o'clock position; and coat the inner bore of nut with Locktite gelatin 277, and finally tighten the nut to torque 470~510ft.Ibs ( 640~ 690N.m) Note: the purpose of putting the thread statt point at the position of 5 o'clock is to keep the liner lock threads from being damaged. Insert liner seal rings (1) into the counter-bore of the wear plate (2), Coat inner surface of cylinder liner lock (4) with grease and then put the two-half liner-latehing ring on the liner and hold them with the O-ring, Lift the cylinder liner and coat cylinder liner lock threads with grease ancl pu the lend thread start point at the position equivalent to 7 O° elock and push while turning the liner into the liner flange (3). Tighten the liner lock (4) and press the liner end face into position and knock the Jiner lock tightly with a hammer.ah a USER MANUAL OF BHF-1300/1600 MUD PUMP 5 6 7 8 9 10 17 _ 18 Sow a Figure 8 7.3 Piston rod Ctean piston tod (7) and piston (8); make sure they are free of burs and nicks, Install O-ring (9) in groove of piston and slide piston (8) on the rod (7) and watching that the O-ring is not distocated out of the groove, Tighten piston rod mut (10) to torque: 1200 ~ 16008.1bs (1625 ~2165N.m) . Coat liner LD and piston O.D 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 it centered at the liner rear part. Drive the piston into the liner with a piece of hardwood or speciat tool, Be carefil that while driving and approaching the crosshead extension rod you do not damage the positioning dowel of the piston rod end. The piston rod must be supported and guided into the extension-rod positioning bore. 7.4 Piston rod clamps ‘The piston rod clemps are machined as one piece and then cut into two halves; and the two pieces are stenciled with matching nurabers and linked together with a chain, They must be used in pairs with the same matching numbers. Before installation of the clamps, the splash- guard (19)ah ae [USER MANUAL OF HHF-1300/1600 MUD PUMP ‘aust be installed on the end of extensfon rod and the clamps clip on the end flange chamfer of the piston rod and extension rod. Tighten bolts to the torque: HHF-1300/1600 ,245f.lbs (330N.m) . ‘When the rods and clamps are new, there is a gap of about 1/2" ( 13mm between the two halves of the clamp to ensure that the end faces of rods form a good ‘mmetal-to-metal’ connection. As wear ‘occurs, the two halves will be pulled closer; ifno gap exists, the clamping force will be lost and the clamps need to be replaced, Finally, install the liner end cover on the rear part of the eytinder liner. 7.5 Lower valve rod guide and eylinder head Install the lower valve rod guide (12) and slip it on valve body, through flashboard (13) press down, the valve rod guide and press the valve spring simultaneously. Install the locating disk (11) into the cylinder bore; install cylinder head O-ring (14) on the eylinder head plug (15). Coat the O-ring and outer circle of the eylinder head plug with lightweight oil. And push the eylinder head plug and knock the end lightly into the eylinder ftont-end inner bore. Coat the threads of the cylinder head with grease; rotate the cylinder head (16) in against and on the plug (15), and then tighten the cylinder head with a force-multiplier tool and hammer provided together with the pump. If the fluid is leaking through the bleeder holes it indicates that the O-rings are damaged or the cylinder head is Ioose. Never block the bleeder. Once the O-ring fails it will cause the head threads, and other parts be ‘washed out” and damaged. 716 Valve pot cover (valve pot cover) Install the valve pot cover seal ring (17) 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, 7. Discharge manifold 5" (127min)5000psi flange is used for discharge manifold, Having removed the flange and the ring gasket, weld the flange to the discharge line (Iypes of welding will be selected by user). Tighten the flange connection bolts and nuts alternately to the torque: 1200 ~ 1600ft.bs ( 1625~2165N.m) . If the other end of the manifold will not be pipeline-connected, a blind flange can be installed andfh, ae USER MANUAL OF HHP-1300/1600 MUD PUMP tighten the bolts and nuts as the way mentioned above. 7.8 Suction flange ‘The suction flange is a 12” (305mm) bore flange, which is custom-made and connected and matched with the inlet flange of the suction line, O-rings seal the flange connection, Before connecting, clean the O-ring grooves and flange end faces and then tighten the bolts to the torque: 360 ~ 490fibs (490 ~ 665N.m) Figure 9 7.9 Accessory manifold ‘The accessory manifold is shown in the figure 9. It may be installed on the discharge manifold and ‘opposite to the discharge filter screen assembly. ‘This accessory manifold is connected with pulsation dampener (1) through the discharge bend- tube assembly; and installed @ 3-8NPT and a 211 V2NPT, the two outlets are connected with reset relief valve (3) and pressure gauge (2) respectively. Note: a bushing wll be used when the pressure gauge interface threads are RL 1/2 ‘The accessory and discharge manifolds are connected by flanges; before installation, clean thoroughly the flange seal ring grooves and then insert the ring gaskets (4), and tighten the ‘connection nuts (5) to the torque: 1200 ~ 16008.Ibs ( 1625 ~ 2165N.m } . To ensure a uniform force is exerted on the seal gaskets connections, tightening the nuts should be done cross-alternately.ae USER MANUAL OF HHP-1300/1600 MUD PUMP. ‘The reset relief valve (3) is installed on the accessory manifold for the purpose of protecting the pup fiom pressure exceeded the rated value and discharge all the fluids fo guarantee safety of the mud pump. The reset relief valve must be installed to be able to contact directly to the mud tanks; ‘and no 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 tine es possible. Ifa tum 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 flange on the bottom of the KB-75 pulsation dampener (I) is supplied together with R39 ring gasket(6); before installation of pulsation dampener , clean the ring gasket and groove thoroughly and after installation, tighten the nuts (7) to the torque: 750~ 850ft Ibs ( 1020~1150N.m) . To ensure balanced forees to be exerted, all nuts should be tightened alternately cross ways. Before starting the pump, pre-charge the pulsation dampener to not be more than 2/3 of the pump discharge pressure. Maximum pressure is not to exceed 650 psi (4.5 Mpa). The pulsation dampener will be charged with nitrogen only. Do not charge with ait, oxygen, hydrogen or other easily-burnt and explosion gases, ‘The charging will be conducted with a set of charging equipment (pulsation dampener charging hoses assembly) provided together with the pump, as shown in Figure 10 and the operation sequences are as follows: i tn Figure 10 1, Nut 3/4-16UNF-2B 2, Seal joint 3. Joint 4, Seal 5. Plug 6. Hose joint 61-2500ae USER MANUAL OF HHF-1300/1600 MUD PUMP 1a, Remove dampener pressure gauge cover, rotate vent valve handle about 1/4 -1/2 of a circle to release the remaining pressure and make the pressure gauge reading retum zeto; remove vent valve capping and plug, b. Connect the nitrogen cylinder valve to the dampener vent valve by a hose c. Open the shut-off valve of the dampener 4. Open the nitrogen cylinder valve slowly and adjust the airflow into the dampener €. Close the nitrogen cylinder valve when the reading of dampener pressure gauge is up to the pressure required £. Close the dampener shut-off valve ‘Remove hose and install the vent valve cap and plug Install the pressure gauge cover; ‘To achieve the best results, the dampener pre-charging pressure must not be more than 2/3 of the pump discharge pressure, and the maximum charging pressure is 650 psi (4.5 Mpa). The pulsation dampener must be charged only with compressed nitrogen and not with oxygen, hydrogen or other easily-bumt and explosive gases. For maintenance of the dampener, the pressure in the dampener must be zero and the pump pressure also is zero. Be careful that don’t fully rely on the pressure gauge readings. The vent valve cap must be open to release pressure, the remaining pressure may be low and the pressure gauge may not read correctly. This tow pressure may still cause an accident. 8 Lubrication It is very important to lubricate properly all moving parts, which dlrectly affects the service life of the parts. To obtain the longest service life without failures for all parts of the power end, regular maintenances and inspections must be done to ensure proper and clean lubrication oils flow to all moving parts. 8.1 Minimum operating speed ‘To Iubricate whole power end, a combination lubrication system of oil bath splash and pressureoh, ae USER MANUAL OF HHF-1300/1600 MUD PUMP. systems is adopted for HHF series pumps. When a gear oil pump is driven mechanically (except driven by a electric motor), the types of pressure system adopted, in fact, govem the minimum, ‘SPM, at which the pump being operated. As for the pressure lubrication systems adopted for HEF scries pumps, they could operate at a minimum 25 SPM; at this time, the lowest oil pressure is $ psi (0.035 Mpa), Bins Pinion shaft il pump gear Figure 11 Note: The pressure lube oil pump could be installed outside of mnd- pump and driven by v-belt or installed inside of mud- pump and driven by big gear rim. When the later installation is used, the rotating direction of the pinion gear should be as shown in figure 11. 8.2 Flow- controlled splash lubrication system The flow- controlled splash lubrication systems are the same for all HHIF series pumps, regardless of the types of oil pump provided for the lubrication system, In the flow-controlled splash system, the big gear rim brings up the oil from the sump; and when its teeth mesh with the pinion, the oil is squeezed out and splashed to various oil troughs and oil cavities in the frame. With reference to figure 13, the oils are thrown into the trough (7) and flow through pipe (8), to the bearings on the two sides of the pinion shat ‘The passage that oil flow from the top of the crosshead guide into the crosshead bearings is shown in figure 12, The oils aecumtlated in oil chamber above the erossheads flow through oil nozzle (5), into the crosshead pin baffle, and then to oil passages (5) to Iubricate crosshead bearing. There areAh ae USER MANUAL OF HHF-1300/1600 MUD PUMP two oil passages (5) symmetrical to axial line andl 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. tog E 2 f 4 3 < ee rete sau ee Ee th ne 8.3 Pressure lubrication system ‘The pressure lubrication systems used for HAF series mud- pumps have installed a lube oil pump, as shown in Figure 13; inthis system, the fltered oil is sucked in, through the suction filter (1), by the pump, and then through the block IL (2), distributed to the pinion shaft nozzle (3A), main bearing oil-pipe (4) and the block I (4A) in crosshead chamber again through the block I (4A), distribute oil to the crosshead, its bearing and extension rod.ae USER MANUAL OF HHF-1300/1600 MUD PUMP ee Figure 13 ‘A pressure gauge (5) is mounted on the back base plate of the frame to show oil pressure in the block oil-istributor, which is obviously changing with the speed of the pump. However, if a sudden pressure drop or increase occurs, the reasons caused must be found according to the section ‘on Maintenance of lubrication system, A pressure relief valve (6) is mounted on the block IL (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) ‘ancl then locked down to avoid the preset pressure changing.‘Upon builtin installation of the lube oif pump, as shown item 9 in Figure 13, the pump mast be well positioned according to the requirements as shown in the Fignre, The side face of the oil pump gear must be flush and parallel with the side edge of the mud pump main gear rim, and the gear teeth have 0.024"-0,0355" (0,60-0.90 mm) backlash A typical layout for oil pump driven by pinion shaft is shown in Figure 14. The oil pump (1) is pipe-connected to the lube oil pipes system through the suction and discharge adapters mounted on the bottom inside walls of the power end. Don’t overtighten the V-belt (2) to prevent the pump from premature damage. To avoid possible injury, the V-belt guard, as shown item 3 in Figure 14, ‘mst be installed before the pump being operated. 8.4 Maintenance of lubrication system Sufficient Iubrication of all moving parts is the most important factor to extend the service life of ‘the pump; being meticulous in maintenance of the lube oil system is a duty forall operators. In fact, 4 good or poor maintenance of the lube oil system determines a long or shott trouble-ftee service life of the pump, ‘The recommended lubrication ofl is as follows; and also shown on nameplate fixed on the pump side. All data recommended are the results of long-period tests in the oil field; therefore, any substitution of oil recommended could only be used for emergency conditions.Lubrication specification: Using extreme- pressure (EP), non-corrosive and anti-foaming gear lubrication oil is specified as follows: Ambient temperature: +30° F~+155° F (4° C~+68° C) AGMA 250.04EP (6EP ) or ISO VG320 Ambient temperature: 0° F~+80° F (18° C~+27° C) AGMA 250.04EP (SEP) or ISO VG220 Ambient temperature: 20° F~+40° F (29° C~+4° C) AGMA 250.04EP (4EP ) or ISO VG150 Oil reservoir capacity: HHF-1300/1600 100 US gel (379L) Every shift should make their rounds to check the oil level and maintain the level at the FULL position; in view of oil level compensation, it is lowed to drive the pump for 5 minutes at « slow speed and make sute the oil level at the specified position, ‘Check onee every 6-month if the oil has any sand and corrosive compounds in it or not; it should be drained, Drain all the oil and flush the oil reservoir before adding new oil. The oil drains are located on either side of the pump frame. During flushing, thoroughly clean the oil troughs and the ‘chambers under the crosshead guides, and also clean or replace the filter element in the suction oil filter, and clean the suction filter sereens. Before filling new oil remove the drain cover from setting chamber and clean out contaminants. Regularly check the condition of the lube oil and replace if contaminated ;moisture in the air, ingress of water and mud, and dirt may enter and contaminate the oil. ‘The setting chamber (deposit chamber) is located in the crosshead guide area of power end; the contamination in the oil splashed into this area is allowed to settle and be drained out by removing the drain cover that located on the two sides of the fame under crosshead inspection cover. ‘Check once every month, Remove drain covers at pump two sides to drain out the contaminated oi from the setting chamber, This will lose about 15-gallons of oil and must be compensated by adding the same amount of oil fo the main reservoir. Check once every week, Remove the 2 1/2” plugs below the frame and drain out the accumulatedah ze USER MANUAL OF HHF-1300/1600 MUD PUMP water. Every shift makes their round of inspection of oil level once and Keep the level to the full position In case of oil pressure drop oceurs; check the following items: ~~ Suction filter screen may be blocked ~~ Oil level may be too low = Vebelt slipped Connections or jaints may be broken or loosen il pump may be worn or damaged ~-- Relief valve may be failed In case of oil pressure increase occurs; check the following items: ~~ Oil pass-way may be blocked -~Contaminations may make the oil be viscous ~~ Relief valve may be inoperative -~ Pressure gauge may be defective ~~ Other abnormal conditions 9 Maintenance 9.1 Power end Regular inspection ofthe power end isthe most important way to conduct preventive maintenance; it could find various failures in time, small or big and enable the mud pump to be repaired according to plan or in the normal shutdown time, 8. Check tightness of the main bearing bolts tothe torque: 975OfLibs (13210 N.M) b. Locking wire Check all bolts including main bearing cover bolts, and check all locking wires on the bolt head of all crankshaR-bearing baffles; after relightening bolts, the locking wires must be replaced. Refer to crankshaft assembly section for bolt torques required ©. Oilpipestine ‘Check all oil pipelines and make sure that they are complete and free of obstructions. Check the pump suction pipelines are free of damage.ah a* USER MANUAL OF HHF-1300/1600 MUD PUMP 4. Suction filter Check suction filter status, clean or replace it if necessary ©. Main bearing cover Remove the main bearing cover; check tightness of main bearing bolts and condition of the boaring rollers. Clean and remove any siudge, dirt or foreign objects, as they might be accumulated in the bottom of the bearing area, §, ‘Teeth of main and pinion gear Check the condition of the main and pinion gear teeth for any sbnormal wear. During the running-in period there will be some pitting on the face of the gear teeth, This is referred to as, “initial pitting” and is not harm to the life of the gears; however, during the regular check if the pitting is expanding, immediately contact the pump manufacturer to inspect the gears thoroughly. g. Crosshead pin bolts and crosshead guide Remove cover and check condition of the crosshead pin bolts and locking wires. (The back cover can be removed and the link (connecting rod) be rotated to outer dead center, while checking middle crosshead pin), Tighter the crosshead bolts (iter 3 in Figure 12) to the torque: 165~ 175ft.bs (225 ~ 240N.m) While tigh ing use @ torque wrench and do not exceed the above-mentioned torque value, Jf the crosshead or guide shows abnormal wear, replace it immediately as it may cause damage to the bearings and other parts and speed up the wear to the piston and cylinder liner by the hh, Labe oil and oil reservoir ‘Check condition of oil and cleanness of the oil reservoir; service the oil lubrication system as specified in the section on Lubrication of this manual, 2 Roller bearing Roller bearings are used for all HHP series mud- pumps. As very precise mechanical parts, ali roller bearings must be carefully maintained to ensure that higher load capacity and longer service Life to be obtained‘Spherical selfalignment roller bearings are used for crankshaft main bearings. The pinion shaft is ‘mounted on short-column roller bearings. The eccentric bearings are single-row short-column with detent ring roller type to facilitate removing. The crosshead pin beatings are double-row Jong-column roller type. None of the bearings require special adjustments. ‘All inner and outer rings are assembled and fited very accurately as the fit clearance of bearings are very small; therefore, they must be used in sets. If one element of @ bearing failed (inner or outer rings, rollers or retainer, it must be replaced in sets. If excessive tolerance clearance, groove ‘or wear in socket ring and spot corrosion or sealing on parts occur; which indicate that these bearings are already failed and must be replaced as soon as possible. All roller bearings are assembled to shafts by shrink fit (refer to every bearing assembly for the bearing fit data), Damaged or wom bearing or socket ring can be removed by driving them off the shaft with a copper rod and hammer or by gas cutting but must be very carefal don’t hurt the shaft Bearings assembling usually use the way heating in an oil bath; but the temperature should be below 300°F (149). Make sure that both the oil and tank must be very clean; if the oil were directly heated by open fire under the oil tank, the beating inner ring must be supported while putting it inthe oi! tank and don’t leave the bearings in the tank longer than 3 minutes. Don't heat the bearings with a torch unless itis the only possible means available, When heating by torch, it must be only operated by an experienced gas-welder; the torch and the bearing must be at least be 6” (150mm) apart. Use a tempil-stick to measure the temperature; don’t overheat the bearings; otherwise, the bearing will become soft by tempering of metal. Once the heated bearing is in place on the shat, it should be naturally cooled, never use water or other liquid to coo! the hot bearing. Rapid cooling will eanse the bearing’s inner and outer rings as ‘well as rollers to be ‘thermal-eracked’ and damaged. ‘Never strike bearing with a steel hammer, upon installation a wood hammer might be used to drive lightly the bearing in place. Usually coat the shaft neck and fixing bores by grease before installation of beating; the best one for this purpose is called as ‘white lead oil’, ie, a kind of anti-seize compound oil. Before installation, open the packaging box and take out the bearings; be sure that prevent any dirt and other foreign objects enter into the bearings; and remove packaging antirust grease and cleandh ae USER MANUAL OF HHF-1300/1600 MUD PUMP all beatings thoroughly with kerosene or other solvents. 9.3 Pinion shaft assembly Figure 15 ‘The fittings between parts on the pinion shaft assembly and bearings are shown in table HII Table It Matching location Marked by Numerical value 70.002" ~ 70.0043" Bering inner rng to shaft nesk A 70.050mm = T0,L09mm 10.0007" ~ Lo.004s* Bearing outer ring to bore B 1L0.618mm ~ L0.11Smm 1L0.003" ~ L0.008" Bearing cari to frame bore © L0.076mm~ 10.203 Jn this table, T indicates interference and L indicates clearance. ‘The gear and shaft are machined as an integrated unit; the fit tolerances of the bearings are determined by their precision fit with the shaft and the bearing carrier. When performing maintenance or overhaul, make sure the requirements in Table III are obtained. Having installed the inner ring and seal sleeve. (15° bevel edge towards outside) of bearing by shrink fit on the pinion shaft neck, the installation of pinion shaft assembly is completed, and then the pinion shaft assembly can be installed in frame bores at any end into the frame assembly (see Figure 15).fh rz USER MANUAL OF HEF-1300/1600 MUD PUMP ‘When installing the pinion components in the frame assembly, the following points should be noted: a Ensure the seal washers (6) of bearing carrier and the end cover seal washers (5) are correctly in place. ‘When installing the bearing carrier (7) and end cover (4), make sure the oil groove is positioned downwards and aligned with the drain hole; moreover, the oil-accumulating bbox on the bearing carrier should also be installed downwards. Remove burs, dents and gouges from outside surface of the seal sleeve (3), and then install end cover (4) in place. Take care when sliding the seal lip over the Keyway on the end of shaft as the lip may be damaged by the sharp edge of the keyway; when sliding seal into the seal sleeve the seal lip is not allowed to be tumed over the cartier edge. Tighten bearing carrier bolts (12) to the torque: 140 ~ 165flbs (190 ~ 225 N.m) Check condition of the pinion bearing inner and outer rings and roller, if there is any ‘wear, galling, scaling and grooving or radial clearance exceeds 0.012” (0.30mm), it is recommended a new one replace the bearing damaged. 9.4 Crankshaft assembly ‘The crankshaft assembly consists of crankshaft, link (connecting rod) (including bearings), and main gear rim and main bearings. The fit tolerances of the bearings are determined by their precisi fit with the crankshaft and the bores related to. When performing any maintenance or overhaul, make sure the requirements in Table IV are obtained. Table 1V “Matching location Marked by Numerical value ‘To.0022" ~To.0048" ‘Main bearing inner ring to shaft neck A T00S6mm~ 10.123: o* 10.0083" Main bearing outer ring to earter bore B (mm ~ 10.108 Bearing inner ring in link(connecting rod) big ‘To.0069" ~ TOOLS" © nd to eccentric outside ring TO.175mm~ T0300hy a* USER MANUAL OF HHP-1300/1600 MUD PUMP. Bearing ovter ring in ink big end to bore in fink 10.0019" ~ Too" D big end 10.0497 ~T0.102mam To.0as" ~ T0093" Inner bore of big rer rim to hub outside round E T0.126mm~70.236mm Lo.002" ~70.002" Main bearing carrer outside round to fame bore F 1L0.05mm~TD.05e0 CCrosshead bearing outside ving to link bore in ‘Fo.0008" ~ 70.003" s mall end To.016mm~T0.076mm Crosshead bearing inner ring to crosshead pin Tooo12" ~T0.0035° H vter round T0.031mm-TO09:m In this table, T indicates interference and L indicates clearance. ‘The crankshaft assembly is installed as follows: (refer to Figure 16) 9.441 Assembly of big gear ri Clean the aligning and mating faces of the big gear rim and outside of the crankshaft hub and ‘heat the big gear rim to the temperature 176°F ~ 248°R( 80°C ~ 120°C )and keep thermal insulation for one hour, and then mount on the crankshaft by shrink fit. When the temperature dropped down to room temperature, tighten the nuts (19) and bolts (11) eross-alternately to the torque: 1810 filbs (2455N. m.Check the diameter and ond plane run-ont of the big gear rim afer installation by the ways as follows: first mount the crankshaft into the frame assembly, and then rotate the big gear rim and measure its diameter run-out on gear rim circle directly by a dial indicator. While measuring the gear rim end plane run-out since it also affects the ruming clearance the of main bearings, it must be measured simultaneously at the shaft end and gear end face by two dial indicators; therefore, the actual run-out at any point is a difference of the two readings. 9.42 Install the inner ring of the eccentric bearing on the crankshaft eccentric shaft neck 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 eecentric 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, 9.4.3 Heat the link big end to the teperature 176°F ~ 248°F ( 80°C ~ 120°C )and install outer ring ofah aF USER MANUAL OF HHF-1300/1600 MUD PUMP. the eccentric bearing, and mark the the matching bearing pair well; When the temperature dropped down to room temperature, install the outer detent ring (5) and Keep its scoop positioned at the bottom and tighten the bolts (20) uniformly to the torque: 44 ~ 66ftIbs ( 60~90Nan) and lock them with stee! wire. 9.4.4 Heat the link small end to the teperature 176°F ~ 248°F( 80°C ~ 120°C), install the outer ring. of the crosshead bearing into the link small end bore according to the matching marks, 9.45 Install the link on the inner ring of the eccentric bearings and install the inner detent ring (4); tighten bolts (20) uniformly to the torque: 44~ 66 ft Ibs (60~90NN. m) and lock them with steel 9.46 Install first main bearings on the bearing carrier by shrink fit and then together be installed on the crankshaft also by shrink fits when the temperature dropped down to room temperature, install detent ring (14) and baffle plate (15). Tighten uniformly the bolts (20) to the torque: 44~ 66ft.Ibs ( 60~90N.m) and lock them with steel wire. Before shrink: fiting, the bearing remember to install the spacers (12).ee USER MANUAL OF HHF-1300/1600 MUD PUMP eal Mnf By a aa \15.27 98 19/ 2025 21/ 17 16 26) Figure 16 &dh, at USER MANUAL OF HHF-1300/1600 MUD PUMP 9.5 Installing crankshaft assembly in fame assembly Jn order to obtain a more precise fit between the main bearing carriers (sleeve) (right and lef) and the frame bore; the following steps should be followed. 9.5.1 Before lifting crankshaft assembly, put piece of woodblock between the link small end and crosshead guide (see Figure 18), to prevent the guide ftom possible gouging as stiding the link in place. 9.5.2 Rotate the main bearing cartier so that its two symmetry planes are parallel with the main bearing boltholes and provide clearance for the main bearing bolts to ensure the main bearing bolts to pass in; and slowly lower the crankshaft into position, 9.5.3 After installing the crankshaft in the frame and before installing the main bearing caps, check the bearing rollers of each row at each side are equally loaded. Tighten the main bearing bolts only when the numbers of inner and outer rollers supporting the dead weight of the crankshaft are equal. Owing to the affects of manufacturing tolerances ete, the total number of the rollers may vary slightly. Bearing bolt Main being Lead wite Beating sleeve (= 0, 60am) erantetat shims (0, $00) Figure 17 9.54 Install and shim main bearing; and make the main bearing carrer have a interference of 0.0024" ~0.004" (0.06mm~0.L0mm) to obtain a pretension through adjusting thefh, xF USER MANUAL OF HHF-1300/1600 MUD PUMP thickness of the shims. There are two ways to decide the thickness of shims: a. Calculate 1) Measuring the outer diameter of main bearing carrier A 2) Measuring the inner bore diameter of main bearing pedestal B, or read directly from frame main bearing pedestal end face. 3)Actual shitn-thickness needed =0.25- C0.10- ( A-B)) mm 4) Tighten main bearing bolts 3-8UN-3A to torque 9750 R.Ibf (13210N.m) . Trial-adjusting method, as shown in Figure 17 1) Put steel shims with thickness of 0.5mm in main bearing cap matching face 2) Add a piece of lead wire (fuse) in the middle of matching area between main bearing cap inner hole and bearing carrier 3) Tighten all main bearing bolts to torque mentioned above, 4) Remove the main bearing cap and measuring the thickness of the lead wire, 5) Pretension of the main beating cap is 0.10 mm 6) Actual shim-thickness needed = shims thickness 0.50 -lead wire thickness pressed — bearing pretension 0.10mm. Note: Different matching tolerances for right and left sides make it necessary to measure and determine the shim-thickness for both sides separately. And then place the shims under the main bearing cap according to the thickness above-determined separately, tighten all main bearing bolts to the torque: 9750 fulbs (13210N.m) . Recheck the load condition of inner and outer two-row roller at both ends as mentioned above, to ensure that each bearing has the same load. 9.6 Installation of crosshead guide 9.6.1Clean thoroughly the surfaces of the guide and frame bore used for installation of the guide and remove all burs or rough edges. 9.6.21F an old guide is to be reused, check the friction surface for wear and scoring etc. If itis not up to the requirements, eplace it Note: As for HHF ~1300/1600-1ad pumps, the upper and lower crosshead guides are not interchangeable. The guides are differently machined so that the lower one places the crosshead ondh x? USER MANUAL OF HHF-1300/1600 MUD PUMP. frame centerline, but the upper guide is machined to afford a certain clearances between the crosshead and guide. The upper guide is thinner and has a big bevel edge at the back part and oil hole in the middle. 9.6.3 When installing upper and lower guides, tighten the guide screws to the torque: 150 ~ 2008 Ibs (200 Nm ~ 270N.m). 9.64Check tightness between frame and guide at point A as shown in Figure 19A with 0.002 “(0.05mm) feeler gauge to make sure guides fit into frame bore properly. 9.7 Installation of crosshead ‘The erosshead can be installed from the front end (fluid end) or guide back end (power end), refer to Figure 19 and follow the following steps: teeter Love guide rosshea: Figure 189.7.1Thoroughly clean all ditt or contaminations and remove all burs or rough edges ftom OD, pinhole of the crosshead and guide inner bore ete. Wipe and dry crosshead pinhole so that the connection with the pin taper bore is made up as ‘metal to metal’ one, See following note, 9.722 Position the small end of the link at the side hole of the erosshead guides. Support the link with a piece of wood so that the erosshead pin can pass through the bore of link small end while sliding the crosshead into the pinhole atthe aligned positions. See Figure 18. 9.733 Install the left side crosshead first and then rotate the crankshaft assembly to make the middle link hole into the middle crosshead; at this time the right link hole backs, remove the splash guard disk (see item, Figure 19); push the right crosshead to the middle extension rod chamber so that enough clearances ate provided for installation of middle crosshead, and then install the right crosshead, Note: If an old guide is to be reused, check the wearing surface for wear and scoring etc. The crosshead might be installed to opposite side of the pump if necessary i.e. the left and right crosshead could be exchange- install 10 the bores, However, don’t install the pin into the taper hole until the crosshead pin baffle (2) is mounted. 9.74 Install crosshead pin baffle (2) and bolts (3), (4); align the taper hole of erosshead with the link small end hole, and push the pin by hand or knock the big end of the pin lightly by a hammer to install the pin into the taper bore. Put the adjusting shims between crosshead pins and baffle {note: as to a set of pin and its hole, the thickness of shims needed are determined and not exchangeable with other shims, otherwise, failures may occur); rotate crosshead pin until the 8 bolt: holes on the pin baffle align with the holes below and install 6 bolts (4) and 2 bolts (3) separately and tighten them by hand (refer to Figure 19 and 19), The ol catcher of cresshead pin baffle should be upwards.ae USER MANUAL OF HHF-1300/1600 MUD PUME oes eat LESSIG Cy CT @ Te | pesky ® faa tan aan 4 ddl Figure 19 Figure 194 Tighten all bolts evenly to torque: 165 - 175f.Ibs (225 ~ 240N.m) and lock them with steel wire, Use torque wrench and don’t exceed the torque specified above, Note: Steps used for pulling out the crosshead pin: Remove 6 bolts (4) and rotating two of them into the “Jack screw" holes (5); tighten the two bolts until the pins become loose, Remove crosshead baile (2) and bolts (3), and then take out the pins from the holes. 9.7Sinsert long feeler gauges in between erosshead top surface and upper guide (8) 10 check running clearance that should not be less than 0.02” (0.508mm). Check with the long fecler gauges over entire surface of erosshead, Note: Over- tightening the bolts (4) of crosshead pin baffle will cause deformations of crosshead ‘outer contact are-face and thus increase eccentrically-worn; at this time, the bolts (4) of the crosshead pin baffle must be loosen and retighten them according to the requirements in 9.7.4 above-mentioned. 9.8 Check crosshead alignment In order to let the piston move comeetly in the liner, the erosshead must travel horizontally along the centerline of the frame hole. To check and align the crosshead as follows: 98.1 Remove the diaphragm stuffing box from the splashguard disk but don’t remove the disk, (Gee Figure 19), 9.8.2 Position the crosshead at the extreme front of its stroke, Carefully measure the distance fromay ae USER MANUAL OF HHP-1300/1600 MUD PUMP. the extension rod to the splashguard disk hole at the top and bottom with inside calipers or telescoping gauges; compare these two measurements to determine the position of the extension rod relative to the centerline of the bore. 9.83 Rotate pump to extreme rear of stroke and take measurements again at the same place as, 9.8.2; compare these measurements with those taken at the front of the stroke to determine if the crosshead is running horizontally. 984 Ifradial clearance difference of the extension rod under the splashguard disk hole exceeds 0.015" (0.381mun), shims should be inserted under the lower guide to make the extension rod rove just towerds the aligned center. In the meantime, enough clearance between the upper and Jower guides should be ensured; in general, the lower guide is loaded heavily and a bigger force is exerted at the back part since the angle of link, thus the lower guide is fast worn; therefore, itis pemnissible to shim the guides a bit skewed to take up the wear, ‘During shimming, the clearance between the upper guide and crosshead upper surface must not be Jess that 0.020" (0.5mm). Larger clearances are acceptable since the characteristics of triplex pump operation and the crosshead pressure is always exerted on the lower guide when clock rotating, Note: When the pump must be driven anti-clockwise the crosshead pressure is exerted on the ‘upper guide, therefore, the guide clearance must be controlled between 0.01" ~0,016" (0.25~ 040mm) 9.8.5 Cut shims being long enough to make them completely pass through the guide; and eut tabs fon the shim: side and exceeding over the frame supports (refer to installation of crosshead guide, 9.6.3 and 9.6.4) 9.9. Maintenance of flutd end ‘With the inerease of pressure used for drilling equipment, the damage to the fluid end often occurs. However, good miaintenances for all parts and components of the fluid end will make them have @ longer and more proper service life, ‘The points requiti ig attention are as follows: 9.9.1 Before starting the pump, make sure all valves installed on the high-pressure dischargeah et USER MANUAL OF HHF-1300/1600 MUD PUMP_ ‘manifold must be open. While the valve are closed, the pump starting will exert an impact stress to ‘the pump and may cause fatigue cracks; and finally the pump head would be damaged by fatigue failure if the situation continued. 9.9.2 Don’t engage the clutch when the prime mover (diesel engine, electrical motor and their dives) is running at a high speed, otherwise, it will cause some additional and undesirable shock. loads against both power and fluid ends. 9.93 Properly maintain high-pressure relief valves and reset pressure according to the cylinder liner installed to ensure that the working pressure is not exceeded. 9.9.4 Don't operate the pump fora long time iffa severe fluid knock is present, Properly maintain the fluid ends for storage, When a pump will not be used for 10 days mote, it is suggested fo remove the pistons, piston rods, liner ete and lush thoroughly the fluid end with clean water and then wiping them clean after Aushings grease all parts removed and all machined surfaces. This will not only extend the life of the fluid end parts but also protects them in good condition to be installed when the pump will be operated again The fluid end assembly for triplex pumps consists of 3 forged fluid cylinder blocks, liner, valve pot cover and cylinder head cover, suction and discharge manifold ete, a Cylinder blocks ‘The structure of the cylinder blocks is shown in Figure 20, Dimensions in Table 5. ‘The 3 independent blocks (3) are connected to the frame of power end through stud-bolts (5); and uided by wear plate outer boss (shoulder or flange) on the eylinder block and aligned by fitting vith the power end frame bores. Upon installation, all burs, dirt and dents ete should be removed from wear-resistance disk outer boss on the cylinder block and all frame inner holes’ mating faces, otherwise there will be warping. TableV Pesition Dimension Position Dimension 8.250" 8.255" 1.120" 1.1307 A H 209.55mm ~ 209.68mm 28.4Smm~28.70mm eipey aad 5,870"~ 5.880" B J 180.97 ~ 181.10emm 149,1Omm~ 149.3Seamat USER MANUAL OF HHF-1300/1600 MUD PUMP. 8.252"~ 8.255" 6247" 6252" c K 209,60mm~ 209.681 158.67mm~ 158.80mm 14.499"~ 14501" 6.630"~ 6.635" D L 368.27mm~368.32mm 168.40mm~ 168.53mm gras? 7378"~7.380" M 635mm 43" 187.32 ~ 187.451 2.995"~ 3" 0.495"~ 0.505" N "76.07 ~ 76.20mm, 12.57mua~ 12.83 0.625"~ 0.630" 15.87mm~ 16.00mm, 16 b, Suction manifold Figure 20 ‘The suction manifold (1) is connected with each cylinder blocks by bolls and sealed by O-ring @) in the connection faces with flange. Before installation, thoroughly clean O-ring grooves and sealing surfaces in the cylinder block, and then insert O-ring; to ensure good seating, the flangedh ee USER MANUAL OF HHF-1300/1600 MUD PUMP connection must be made up ‘metal to metal’ to retain the O-ring seal, therefore, any nicks, grooves or galling on the sealing surface must be repaired. Refer to the following section 9.10: ‘Welding and Repair, ofthis Manual for detailed repairing steps. Before tightening the bolts of suction manifold (4), the four bolts (4) on the three cylinder blocks ‘ust be well started in but not tightened, finally tighten them to torques indicated in Table VI with torque wrench (see description below). c Discharge manifold ‘The discharge manifold (8) is fixed on each eylinder block with stud bolts (10) and nuts (11) and sealed by O- rings. Before installation, thoroughly clean O-ring grooves in the cylinder block and scaling surfaces on the dischange manifold; and the connection must be made up ‘metal to metal” to retain the O-ring seal, therefore, any nicks, grooves or galling on the sealing surface must be repaired. Refer to the following section 9.10: Welding and Repair, ofthis Manual for details. Before tightening the bolts of discharge manifold (11), the four bolts (11) on the three eylinder blocks must be well started in but not tightened, finally tighten them to torques indicated in Table ‘Vi with torque wrench (see description below). D. Cylinder head flange (cylinder thread ring) “There are threads in cylinder head flange bore to facilitate removing of eylinder head (head); the flange should be replaced if damaged. Before installation, thoroughly clean all burs, cutting edges or foreign objects on the mating faces and install the flange “leakage groove” downwards. To censure its end-face is perpendicular to the axial-ine of the cylinder block, a ‘metal to metal” ‘connection on the matching faces between eylinder head flange and eylinder must be made up. All nuts (11) must be tightened to the torque as shown in Table VI: Table VI Position Ttem no. in figure. Torque ft.ibs Torque Nm With fame 5 1600 2170 Suction manifold 4 240 225 Discherge manifold 10. 11 1000 1385 Cylinder hea flange 7 1600 2170Ee USER MANUAL OF HIF-1300/1600 MUD PUMP 9.10 Welding and repairs ‘When repaiting bores, for normal wear or being badly washed in the fluid end, the following welding procedures must be strictly followed and all dimensions of the bores patched up be machined to size specified in the Table V. In all cases, the bores’ shoulders (for installing. cylinder liner, cylinder head ete.) must be 90° to the axes line of the bores, 9.10.1 Welding procedures Distinction should be made between welding the pricks and eracks; the following are some basic information for welding: a. Procedure Welding as per the way used for 30 # carbon steel ~-Bofore welding, clean area to be welded by grinding or carbon-arc-ait-gouging, be sure the electrodes are dry and free of moisture, and if necessary, put them in an oven to dry before welding, ~ Spot-heat the welding area, at least for a surrounding 3” (7Smm) area, to 250° F~ 350 * F (120° C~ 180°C). ~-Use low-hydrogen rod: AWS-ASTM B-60-7018, such as ADAM-Atc7018 ~-Temperatue should be dropped down to 250° F~ 350° F (120° C~ 180" C) after one, welding seam was completed and then start welding the second. After all patches were completed, heat to 250° F~ 350° F (120° C~ 180° C) agein and then start “thermal-insulation-cooling’. Cracks: Grind out all cracks. It is not recommended that to remove cracks by torch cutting since it ‘will cause the cracks to enlarged, ~Preheating: the purpose of preheating is to expand the area to be heated so that when cooling, the welded area and the preheated area will cool more uniformly, thus to avoid ‘thermal cracking’ and prevent the “hard spots’ forming between the base metal and the ‘welding metal’; ‘These hard spots are just the places the fatigue cracks will star. ‘The welding procedures for cracks are the same as above-mentioned,dh aF USER MANUAL OF HHP-1300/1600 MUD PUMP 9.11 Repair to valve pot cover bore ‘When repairing the valve pot bore damaged by washouts keep the valve pot cover seat completely level and 90° to the axis of the threads are most important while tuming or boring the valve pot bores. As shown in the Figure 21, the valve pot seal ring (1) seats into the counter-bore at the top ‘of valve pot and forms ‘metal to metal? contacts; the seal ring was sealed in the lower point machined by tuming or boring, otherwise, a gap will be formed between the end faces of valve pot bench and valve pot bore, through which the seal ring will be extruded and damaged under pressure, Any high or low spots could also eause the valve pot to become ‘warped! and result in severely damaging the threads. . Metao meal conection S Figure 21 9.12 Replacement of the bladder (air-bag) of dampener While replacing the dampener, the following procedures must be followed: (see KB-75 air dampener assembly): 9.12.1 Make sure the pressure in the system is completely released. (See the above-mentioned) 9.12.2 Remove the cover (5), which can be jacked out by using two removing threaded holes; if the stud-bolt was rotated out from the shell while removing, first remove the mut (R2), and then clean the bolts and holes, rotate again the stud-bolts into the holes with the stud-bolt spanner or putting two muts together tightly with a spanner and finally tighten them to torque: 670 ft.lbs (910 Nem)dh, ad USER MANUAL OF HHF-1300/1600 MUD PUMP. 9.12.3 Remove the daunpenet: insert a stick in between the shell and bladder and fold the bladder ‘and take itout from the top. 9.12.4 Chock the condition of the bladder, good or damaged; if damaged inspect any swell or foreign objects in the damage-related place and the shel inside; and eliminate all factors caused. the damage, 9.12.5 Check the condition of the bottom plug and its all edges must be smooth. It must be replaced if damaged by wears, and have a interference of 0.003" ~ 0.006" ( 0.076 ~ 0.152 mm) 9.12.6 Install new bladder Roll and coil the bladder as a spiral-shaped until it can be installed from the upper opening and then stretch and adjust the bladder to make it fit closely withthe shell, finally push the sealing ring at the dampener neck to the shell opening and coat the inner side of dampener neck with greases. 9.12.7 Install the cover (5) and be sure not extrude or deform the bladder. 9.12.8 Tighten the nut (R2) to torque: 1200 ~ 1600 filbs (1625 ~ 2165N.m). 9.12.9 Change the bladder as required and specified by section of accessory manifold 7.9. 10 Daily maintenances of Pump To maintain the pump properly is a necessery measure to ensure the pump is working correctly and extend its service fife. Importance should be attached to this key task during operation, 10.1 Daily maintenanees 10.1.1 Shut down the pump and check oil level at power end. Check once each day; if the pump is riven by chain transmission the oil level in chain reservoir should also be checked. During ‘operation, the Inbe-oil pressure changes in the system shown on the oil pressure gauge should be checked. 10.1.2 Observe working status of the cylinder liner and piston; if a little bit mud-leakage is found it is nommal, but if mud leaked is excessive the piston needs to be replaced and the eylinder finer ‘wear shoul also be carefully checked. If excessive wear is found replace the liner. 10.1.3 Check the liner cavity of the frame and wash out the accumulated mnd. 10.1.4 Check the cooling water quantity in the spray pump water tank, Replenish and replace the contaminated cooling water if necessarydh ze USER MANUAL OF HHF-1300/1600 MUD PUMP. 10.1.5 Check the charging pressure of discharge dampener up to the requirement specified. 10.1.6 Periodically test reset safety valve. 10.1.7 Loosen the piston rod clamp everyday and rotate piston about 1/4 turn, and tighten the 0.11” (3mm), replace immediately, E 10.2.2 Check the valves and valve seats and replace those wom. (Note: when replacing a valve seat, he valve should also be replaced.) 10.2.3 Check the piston locking nuts and replace if washed or damaged. (After the nuts have been tightened three times they should be replaces as the plastic locking insert is wom out. 10.2.4 Drain water from the clean out cover phigs until the oil comes out. 10.3 Maintenances every month 103.1 Check all stud-bolts and nats of fluid end, such as, cylinder head flange (cylinder thread ring) muts, connecting nuts between cylinder block and frame, bolts and nuts installed for suetion ‘and discharge manifolds etc. Retighten them to the torque as specified if any loosening was found, 10.3.2 Check the seal rings in the extension rod diaphragm stuffing box, and replace those wom ‘out, In general, the seal rings should be replaced every three months and while replacing, pay attention to the installing direction as shown in Figure 22)»| a USER MANUAL OF HHF-1300/1600 MUD PUMP. Figure 22 Oil seals assembly 10.3.3 Remove and clean the filter element installed in the discharge filter 10.34 Replace the contaminated oils in power end reservoir and crosshead settling chamber (@eposit chamber) every 6 months and atthe same time, clean all oil grooves and lines. 10.4 Maintenances every year 10.4.1 Check the tightness of the crosshead guide and running clearance up to the requirements or not, if not it could be adjusted by adding shims under the guide, If the crankshaft assembly is removed for any reason it is recommended to rotate the crossheads 180° for use again 10.4.2 Itis recommended to inspect the pump fully every two or three years; check the wear and damage status of the main bearings, eccentric bearings, crosshead and pinion bearings. Replace with new if excessive wear on the old part. 10.4.3 Check all gears’ wear, if severely wom out in one face, the crankshaft and pinion shaft may bbe turned to use the gear’s other unworn face. 10.5 Other points for attention in maintenance 10.5.1 Wipe the 25° taper face clean before instaling the piston and extension rod clamps. 10.5.2 While replacing the cylinder liner the liner seal rings must be replaced together. 10.5.3 The pump was shut down or temporarily be shut down for more than 10 days. 10.5.4 Close all inspection covers well to prevent the oil from being contaminated by sand or dir. 10.5.5 The pulsation dampener will be changed only with compressed nitrogen or other inert gases.ft, re USER MANUAL OF HH-1300/1600 MUD PUMP Do not charge with oxygen or hydrogen or other easily-burnt and explosive gases. 11 Possible failures and how to eliminate them 11.1 Faitures of fluid end Failures Caused by Methods to eliminate 1. Gauge pressure dropped and ‘output reduced. Suction manifold is not sealed tightly and air entered Jno pump. 2 Suction filter screen clogged, 1. Tighten all suction ange bolts or replace gaskets. 2. Stop pump and clean the, filter 2Fuid discharges are non-uniform and pulsations are ubject to sudden change, gauge pressures vary greatly, wheezy sound can be etd suction ‘manifoe 1.One piston or one valve severely wom or damaged. 2.Air entered into cylinder, Replace damaged piston: open valve pot cover and check valves 2. Check suetion manifoa's and valve pot covers tightness. 3. Severe knock could be heard 1.Lo03e piston nut 2.Loose eylinder head gland. 3.Poor suction [Tighten piston muts, 2.Tighten cylinder head gland. 3.Check reasons for poor suction, Leak at indicator hole of valve ot cover or cylinder head and ine sealing places 1.Loose valve pot cover and cylinder head 2.Seal rings damaged. Lifighten valve pat cover and cylinder head 2 Replace damaged seal rings. ‘S.Discharge dampener cannot be charged of leaks down soon afier charging Discharge connection blocked. 2.Dampener’s airbag broken, 3Needle valve was not tightly sled, 1, Remove dit in connection 2.Replace damaged airbag, 3.Repair or replace the damaged needle stop valve. 6. Motor is heavily-londed 1 Discharge filter clogged Remove filter semen, and clean,dh, ee USER MANUAL OF HHF-1300/1600 MUD PUMP_ Failures Caused by Methods to eliminate 1 Bearings overheating 1 Ol pipe orhotes clogged | 1 Clean oil pipe and holes. 2 Lube cit isto diy 2 Replace old with new cl 3 Roller bearings are worm | 3 Dismount bearings and find out ut or damaged, reasons, replace damaged bearings 2 Some knoeks could be beard in power end. 1 Crosshead guide worn-out 1 Adjust clearance or replace guide 2 Wom bearing 2 Replace bearing, 3 Loose crosshead guide 23 Tighten guide screws. 4 Airhammer in fuid end “A Improve suction performance. 12 Long term storage. 12.1 Ifa mud-pamp will not be used for along period, it should be mothballed. 12.2 Before mothballing, all fluids in the fluid end should be drained out, remove all dirt, wash with water and wipe clean, Coat all machined surfaces of all parts and components in the fluid end with grease, 12,3 Drain out all lube- oils in power end oil reservoir, crosshead guide at two sides, oil-settling chamber and remove all accumulated diet 12.4 Coat all machined surfaces on all bearings, crosshead, gears, piston rod, extension rod ete with heavy oil 12.5 Block all suction and discharge flanges with blind plates. 12.6 Seal all crosshead hole end cover, back cover, inspection-opening cover etc tightly. 13 Special Tools List For HHF—1300 / 1600 Mud Pump, delivered together with the pump oc = Te |& ae USER MANUAL OF HHF-1300/1600 MUD PUMP HHF-1300/1600 GH3161-26.00 Special tools ' 1 | GH3161-26.01.00 Crowbar, cylinder head 1 2 | Guisi6i-26.0200 Hoisting tol for liner 1 3. | GH3161-26.03, Socket wrench 23/8" 1 4 | Gust61-26.08 Socket wrench 2° 1 5 | GH3161-26.05 Socket wrench 35/8" 1 5s | Gx3161-26.05 Socket wrench 1/2" 1 7 | cus161-25.07 Socket wrench 15/8" 1 8 | GHaie.-2608 Extension red 19 5/8" 1 9 | cxsi61-25.09 Extension rod, 8” 1 10 | GH3161-26.10 Joint, 1" 1 at | GH3161-26.11 [Extension rod ,24” 1 12 | wBrr7s3494 ‘Chain block, SAN2 1 1B | syB2 Manual oil pump, 0~ 63 MPa ( 0~ 9150psi) L ta | Guai61-26.12.00 Hydrautievalve-paller ' 1s} GH3161-26.13 Intermediate taper sleeve 1 1s | GH161-26.14 Pressing sleeve 1 17 | GH3161-26.15.00 Socket wrench, long 1 18 | GH3161-26.16 Bolt, 1-8UNC-2A * 160, 1 19 Allen wrench, 5/8" 1 20 | GH3161-26.17.00 Flashboard puller 1 21 | GHB161-26.18 Socket wrench, 1 11/6" 1 22 | GH3161-27.11.00 (Charging hose assembly, dampener 1 14 Spare Parts List For HHF—1300 / 1600 Mud Pump, delivered together with the pump. DWG CODE No. Name ay HHF-1300/1600fe at USER MANUAL OF HHF-1300/1600 MUD PUMP i161-2900 Spare pars wih md pup 1 | oxavetaan ile, 2125" 10378" +0625" a 2 | ansisi-o606 Oi sea ng 3 2 | croi6i-o407 Double lipolse, 5° 625" x 0.635" 6 + | craisi-osos Sealrng ender head 3 5 [onsisi0si.0 Rubber valve o 6 | onsto1-05.2 Salting vale pot cover 3 7 | ansiev0sia Sealing, ner 6 ¢ | cusie10s24040200 Robber 6 V2" 3 9 [ones Sealing, piston 3 10 | onai61-0s2901 Rubber ell (auton danpener) 1 | casis1-09 Seal washer a 12 | anstorazes ca) Seal ng, R35 (te) a | crot612206.2 Seal ng R21 (te) A ve | cuaisias Seal ng Ra (ee 3 15 | ouatsi2re Sealing R39 (ee 1 16 | cusier270300 Aircel (adden, csharge damper : 17 | ousiera80s00 Piston ately, lit vale 1 8 | onev2808 Bumper pa 1 vw [orn shear pin 0 20 | aarr3asa 1982 Oring, 903.550, 3 a1 | Gartaisa i992 Oing95*5.30 3 [ 22 | GB/T3452.1-1992 Oring,125 * 7.0G 3 a | @urtsase i992 Oring.t60*7.06 4 24 | cartes 992 Oning.65* 7.06 1 [ 25 | GB/T3452.1-1992. Oring, 190 * 7.06 3 r 26 | GB/T3452.1-1992. Oring,200 « 7.06 3 a7 | carsa iss O1ing245 «700 3oh Note: USER MANUAL OF HHF-1300/1600 MUD PUMP 1) When with the five-way discharge assembly, then make use of the Seal ring R35(NO.12), with discharging elbow assembly, use the Seal ring R27 (NO.13). 2) When the HP relief valve is in other structures, the part No.17, 18, and 19 are not necessary. 15 Recommended Spare Parts List (HPHF-1300/1600 Mud Pump ) No. Dwg. Code Name ay 1 | GH3161-03.11 Oil seal 9.125" « 10375" «062° a 2 | cxsi61-o405 Oinseal ring s) 3. | GHsi6i.0407 Double lip seal rng, 5” * 625" 0.625" 6 4 | oHB161-04.12 Intermediate extension rod 3 5 | GH3161-05.04.00 Flashboard assembly 3 6 | GH3161-05.08 Sealing, cylinder head 6 7 | Gu3161.05.10 Spring, valve 6 8 | GH3161-05.11.00 ‘Valve assembly, APIT® 4 9 | GHS161-05.11.03 Rubber, valve 4 10 | GH3161.05.12 Seal ring, valve pot cover 6 MW | GH3161-05.14 Seal ing Liner 2 12 | GHBI61.05.15 Abrasion proof dive (wear plate) 3 13. | oxsi61-05.18 Piston rod 3 14 | Gu3161-05.21 Bi-metal lines 51/2" 3 1s | GH3161-05.21 Bi-metal liner 6" 3 16 | GHat61-05.21 Bismeral liner 6 U4" 3 17 | GH3161-05.21 Bicmetel liner 6 1/2" 3 18 | GH3161-05.21 Bi-meta liner 6 346" 3 19 | GHB61-05.214 Liner, * 3 20 | GUS161-05.24.01.00 Piston §1/2° 3a USER MANUAL OF HHF-1300/1600 MUD PUMP. 21 | GH3161-05.2401.02.00 Rubber 6 22 | GUB161-05.2402.00 Piston 6" 3 23. | GH3161-05.24.02.02.00 Rubber 6 24 | GHB161-05.2403.00 Piston 6 34" 3 25 | GHB161-05.2403.02.00 Rubber 6 26 | GH3161-05.24.04.00 Piston 6 12" 3 27 | GH3161.05.2404.02.00 Rubber 6 28 | GH3161.05.2405.00 Piston 6346" 3 29. | GH3161.05.24.05.02.00 Rabber 3 30° | GH3161-05.24.06.00 Piston 7" 3 31 | GH3161-05.24.06.02.00 Rubber 3 32 | GHBt61-08.31 Seat ring, Piston 6 33. | GH3161-05.32.00 Piston Nat, 3 34 | GH3161.05.33.01 Rubber cell (setion dampener 1 35. | Gex3161-27.03.00 Rubber eel (dishorge dempener) 1 36 | Gu3161-28.03.00 Piston assembly (relief valve) i 37 | GH3161-28.06 Bumper pad (relief valve) 5 38 | GH3161-28.11 ‘Shear pin 6 39 | GB/T34s2.1-1992 Oring 190% 3.556 6 = 49° | @prr34s2.1-1992 Oring 95%53G 6 Par | corrasa. 1952 Oring 1257.06. 6 42 | Gprrs4s2.-1992 Oring 160% 7.06 6 43 | Gprr4s2.-1992 Oring 165% 7.06 2 a | cors2.1992 | Oring 190% 706 6 45 | oamr3s2.-i992 Ong 200706 6 46 | Gprrses2.1.1992 Oring 345% 7.06 6 Note: iz 1) When HHF-1300/1600 mud- pump leaves factory, it is equipped with three(3) set of 6 1/2” liner and piston.ze USER MANUAL OF HHP-1300/1600 MUD PUMP 2) [fuse other type of HP relief valve, the parts No.36, 37 and 38 are not necessary, 3) This lists only for one pump unit. Sate: BEE HE: HUE: TIRE St Fae We: October 18, 2005