Install, Care and Operate Triplex Pump Manual

Installation, Care and
Operating Manual
A-600-PT
Triplex Piston Pump
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

A-600-PT Triplex Piston Pump
ADDITIONAL CODE SDRL CODE TOTAL PGS
This document contains proprietary and confidential information National-Oilwell L.P.
which belongs to National Oilwell; it is loaned for limited purposes 1530 W. Sam Houston Pkwy. N
REMARKS only and remains the property of National Oilwell. Reproduction, in
whole or in part; or use of this design or distribution of this Houston, Texas 77043
MAIN TAG NUMBER DISCIPLINE information to others is not permitted without the express written USA
consent of National Oilwell. This document is to be returned to Phone + 1 713 935 8000
National Oilwell upon request and in any event upon completion of
CLIENT PO NUMBER the use for which it was loaned. Fax + 1 713 935 8382
 National Oilwell
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
Client Document Number A-600-PT-MAN-001 02
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Document number A-600-PT-MAN-001
Revision 02
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REVISION HISTORY
02 12.02.2005 Updated to new template PG

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

02 Updated to electronic format from pdf to ms word in new template
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FOREWORD
This manual is published as a guide for the normal operations of your NATIONAL-
OILWELL equipment. Because of the many factors which contribute to the proper function or
malfunction of this machinery and not having complete knowledge of each factor or combination
of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this
presentation, and when situations encountered are not fully encompassed by complete,
understandable instructions, these situations must be referred to the manufacturer.
When other than routine servicing is necessary, it can be most efficiently performed if the
unit is removed to an area of adequate space where an overhead crane, hydraulic lift, bearing
pullers, impact tools, etc., are accessible.
The dimensions and tolerances specified in this publication are those desirable for the most
efficient operations of the equipment. When components become worn or when new parts are
introduced into a worn unit, it may not be possible or economically feasible to reestablish such
strict alignment and correct all dimensional deviations.
Improvements in design, engineering, materials production methods, etc., may necessitate
changes in these products and result in inconsistencies between the contents of this publication
and the physical equipment. We reserve the right to make these changes without incurring any
liability or obligation beyond that stipulated in the purchase contract.
THE PICTURES, PHOTOGRAPHS, CHARTS, DIAGRAMS, DRAWINGS, VERBAL
CONTENTS AND SPECIFICATIONS CONTAINED HEREIN ARE NOT TO BE CONSTRUED AS
GIVING RISE TO ANY WARRANTY ON THE PART OF NATINAL-OILWELL. NATIONAL-
OILWELL MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, BEYOND THAT
STIPULATED IN THE PURCHASE CONTRACT.
CAUTION
Exercise safety in all performances, do not ignore any cautions, use only approved
methods, materials and tools. Do not permit any function of questionable safety because
accidents are caused by unsafe acts and unsafe conditions. SAFETY IS YOUR BUSINESS AND
YOU ARE INVOLVED.
Before performing any service function be certain that the unit is separated from its power
source or that the power source is locked-out to prevent any form of energy from entering the
equipment – this would include electrical or mechanical energy into or from the prime mover/s,
pneumatic energy from the compressor/air system, etc. The traveling equipment should be
suspended from the hang line and the mechanical brake released to ensure there is no load on
the drum that may cause unintended rotation. The sub-assemblies of this unit represent massive
weights and must also be suspended before being released from their operating positions.
NOTICE
FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS
PUBLICATION CAN RESULT IN PROPERTY DAMAGE, SERIOUS BODILY INJURY OR
DEATH.
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TABLE OF CONTENTS
FOREWORD ............................................................................................................................... 3
1 INTRODUCTION ............................................................................................................... 7
2 GENERAL DESCRIPTION ............................................................................................... 8
3 FLUID END ASSEMBLY .................................................................................................. 9
3.1 General ................................................................................................................. 10
3.2 Maintenance ......................................................................................................... 10
3.3 Removal ............................................................................................................... 10
3.4 Installation ............................................................................................................ 11
4 VALVE SERVICE............................................................................................................ 11
4.1 General ................................................................................................................. 13
4.2 Maintenance ......................................................................................................... 13
4.3 Removal ............................................................................................................... 13
4.4 Installation ............................................................................................................ 13
5 PISTONS AND LINERS .................................................................................................. 14
5.1 General ................................................................................................................. 15
5.2 Maintenance ......................................................................................................... 16
5.3 Removal ............................................................................................................... 16
5.4 Installation ............................................................................................................ 17
6 POWER END .................................................................................................................. 19
6.1 General ................................................................................................................. 20
6.2 Maintenance ......................................................................................................... 20
6.3 Removal ............................................................................................................... 20
6.4 Installation ............................................................................................................ 20
7 DIAPHRAGM ASSEMBLY ............................................................................................. 22
7.1 General ................................................................................................................. 23
7.2 Maintenance ......................................................................................................... 23
7.3 Removal ............................................................................................................... 24
7.4 Installation ............................................................................................................ 24
8 CRANKSHAFT ASSEMBLY .......................................................................................... 25
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8.1 General ................................................................................................................. 26

8.2 Maintenance ......................................................................................................... 27
8.3 Removal ............................................................................................................... 27
8.4 Installation ............................................................................................................ 30
9 CROSSHEADS ............................................................................................................... 33
9.1 General ................................................................................................................. 34
9.2 Maintenance ......................................................................................................... 35
9.3 Removal ............................................................................................................... 35
9.4 Installation ............................................................................................................ 37
10 CONNECTING RODS ..................................................................................................... 40
10.1 General ................................................................................................................. 42
10.2 Maintenance ......................................................................................................... 42
10.3 Removal ............................................................................................................... 42
10.4 Installation ............................................................................................................ 43
11 GEAR UNIT .................................................................................................................... 45
11.1 General ................................................................................................................. 47
11.2 Maintenance ......................................................................................................... 47
11.3 Removal ............................................................................................................... 47
11.4 Installation ............................................................................................................ 49
12 COUNTERSHAFT ASSEMBLY ...................................................................................... 53
12.1 General ................................................................................................................. 54
12.2 Maintenance ......................................................................................................... 54
12.3 Removal ............................................................................................................... 54
12.4 Installation ............................................................................................................ 55
13 LUBRICATION................................................................................................................ 58
13.1 General ................................................................................................................. 60
14 LUBRICATION SYSTEM ................................................................................................ 62
15 LINER FLUSHING SYSTEM .......................................................................................... 64
16 STRAINER MAINTENANCE .......................................................................................... 66
16.1 Maintenance ......................................................................................................... 67
16.2 Removal ............................................................................................................... 67
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16.3 Installation ............................................................................................................ 67

17 TECHNICAL INFORMATION ......................................................................................... 69
18 APPENDIX ...................................................................................................................... 71
18.1 Maintenance ......................................................................................................... 71
18.2 Trouble Symptoms................................................................................................ 73
18.3 Torquing Values.................................................................................................... 76
18.4 Torquing Sequence .............................................................................................. 77
18.5 Shear Blocks......................................................................................................... 82
18.6 Storage of Pumps ................................................................................................. 84
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1 INTRODUCTION
This manual is published as a guide for the disassembly and re-assembly of your unit. The
recommendations made here for the performance of normal servicing are based on many
years of experience in the manufacturing, maintenance and servicing of this equipment;
however, unusual or extreme circumstances may arise and these must be referred to the
manufacturer’s technical services department.
Improvements in design, engineering, materials, production methods, etc., may necessitate
changes in this produce and result in inconsistencies between the contents of this
publication and the physical equipment. We reserve the right to make these changes
without incurring any obligation for equipment previously or subsequently delivered.
The manufacturer will upon request and contract provide trained, experienced personnel to
assist you in the maintenance and servicing of this machinery.
The materials used in construction of National Oilwell mud

pumps are suitable for use in sour gas (Hydrogen Sulfide) environments ONLY if the drilling
fluid and environment is controlled as specified in the National Association of Corrosion
Engineers (NACE) Standard MR-01-75, 1984 Revision. Paragraph 11.2 and particularly
subparagraph 11.2.2 which provides:
“11.2.2 The drilling environment is controlled by
maintenance of drilling fluid hydrostatic head and
fluid density to minimize formation fluid in-flow and by
the use of one or more of the following:
(1) maintenance of pH 10 or higher to neutralize H2S
in the drilled formation, (2) use of chemical sulphide
scavengers, and (3) use of a drilling fluid in which oil
is the continuous phase”
Failure to control the drilling fluid environment as specified above can result in sulphide
stress cracking of certain pump components. Such cracking may result in subsequent
failures causing serious personal injury and/or property damage.
NOTE:
1. All Chain in left in English, i.e. Pitches in Inches
All Fasteners left in English
LENGTH SYMBOL DEFINITION
m meter
cm centimeter
mm millimeter
Pressure kg/cm2 kilogram per centimeter squared
Power kw kilowatts
Weight kg kilograms
Temperature °C degrees Celsius
Volume L liters
Flow Rate L/S liters per second
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2 GENERAL DESCRIPTION
Variations in requirements may demand relocation or the omission of certain components

on a specific pump, therefore, please inspect your unit and become familiar with its
equipment and details.
The basic pump is comprised of a power end and a fluid end mounted on a short steel skid.
The power end contains the shaft assemblies, connecting rods, diaphragms, etc. The fluid
end contains the fluid chambers, suction manifold, discharge manifold, valves, pistons,
liners, etc.
The lubrication system with its provisions for filtration; the liner flushing system with its
circulation unit; the features of a piston rod back-up tool, the mechanical turning device,
etc., are all added to the basic unit to compose the standard unit as outlined in this
publication.
The laterality of the unit is, as reflected here, determined by standing at the power end and
looking toward the fluid end – reference is made to the left hand side and the right hand
side. The fluid chambers are also designated from this same position – the No. 1 fluid
chamber is on the left hand side, the No. 2 chamber is in the center and the No. 3 chamber
is on the right hand side.
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3 FLUID END ASSEMBLY
The fluid chambers are three separate blocks or cylinders which are bolted to the power
frame and assembled with the suction and discharge manifolds. The valve seat bores and
the liner adapter bore are machine formed into each cylinder.
1. Fluid Chamber (7) Piston Rod Extension

2. Suction Manifold (8) Liner
3. Discharge Manifold (9) Liner Wear Plate
4. Valve Cover (10) Liner Adapter
5. Piston Assembly (11) Liner Nut
6. Piston Rod (12) Liner Flushing Shield
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3.1 General
The individual cylinder design makes possible the replacement of a single segment rather
than the replacement of a complete, one piece, three cylinder, mono-block fluid end. The
suction and discharge manifolds are bolt-on type and are also individually replaceable.
3.2 Maintenance
1. Maintain proper tightness of all fluid end bolting.*
2. Care should be taken to maintain clean and undamaged gasket surfaces, “O” ring
surfaces and mating metal-to-metal surfaces.
3. Keep valve covers tight. Refer to VALVE SERVICE in this publication for instructions.
4. “Tell-Tale” holes have been provided in the valve chambers. Any leakage past the
valve cover gasket will be discharged through these openings. If leakage is detected,
immediately tighten the valve cover or replace the gasket otherwise fluid cutting or a
wash out will occur.
5. Refer to PISTONS AND LINERS and VALVE SERVICE in this publication for additional
maintenance
3.3 Removal
i) Remove the suction manifold and the discharge manifold. NOTE: The suction and discharge
lines should be drained before removing the manifolds
ii) Remove the valve covers and the valve assemblies. Refer to VALVE SERVICE in this
publication for instructions.
iii) Remove the piston and liner assemblies. Refer to PISTONS AND LINERS in this publication
for instructions.
iv) Support the fluid end segments and prepare to remove only one segment at a time. Remove
the hex nuts at the bottom of the fluid chamber, then the hex nuts at the top of the segment.
v) With the fluid end segment properly supported and secured on a worktable unscrew and
remove the liner adapter. It may be necessary to use chain tongs on the reduced portion of the
adapter for this removal.
*Torquing values will be found in the APPENDIX of this publication.
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vi) Clean and inspect the liner wear plate for damage and corrosion pitting. If it must be replaced,
weld a puller bolt to the liner wear plate and use a weighted “knocker” to remove the liner wear
plate. NOTE: A puller assembly can be furnished for units of the latest design. Remove the
wear plate gasket.
3.4 Installation
• Carefully clean and inspect all parts for damage defects and wear – replace if necessary.
• Place the gasket on the liner wear plate and press the plate into position inside the fluid
chamber.
• Coat the fine threads on the liner adapter with a good quality anti-seize compound and screw
the adapter into the fluid chamber. Use heavy chain tongs on the reduced portion of the
adapter and apply a force in excess of 2,000-lb/ft torque.
• Position the fluid end segment on the power frame and retain snugly, but not tight with the
upper and lower hex nuts.
• Install the discharge manifold. Be certain that the “O” rings are in place and tighten the hex
nuts.*
• Install the suction manifold. Be certain that the gaskets are in place and tighten the hex nuts.*
• The installation of the discharge and suction manifolds should have aligned the fluid end
segments, check to be certain that this has been accomplished, then apply full torquing to the
upper and lower fluid end retaining nuts.*
• Install the piston and liner assemblies. Refer to PISTONS AND LINERS in this publication for
instructions.
• Install the valve assemblies and covers. Refer to VALVE SERVICE in this publication for
instructions.
• Before returning the pump to service refer to and be guided by the instructions listed under
PLACING IN OPERATION in your operators manual.
4 VALVE SERVICE
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The valve chambers conform to API standards and the valve assemblies are
interchangeable – suction and discharge. The chambers are drilled with “tell-tale” holes
which provides for the detection of leakage at the valve cover gasket.
(6) Valve Nut

1. Valve Cover (7) Valve Disc
2. Valve Cover Gasket (8) Valve Body
3. Upper Valve Stem (9) Valve Seat
Guide (10) Valve Seat Bushing
4. Upper Guide
Bushing
5. Valve Spring
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4.1 General
The valve seats are conical and fit into tapered bores in the fluid chambers. The valve
stems are guided, both top and bottom, and have a replaceable, flexible, elastomer, insert
type disc to seal against back flow.
4.2 Maintenance
1. The valve seats must be retained firmly in place to prevent serious damage to the pump.
2. Periodic replacement of the valve disc, prior to fluid cutting will extend the life of the valve body
and valve seat.
3. Systematic replacement of the upper and lower valve stem guides will provide for the proper
seating angle of the valve into the valve seat.
4. Replace damaged or fluid cut assemblies immediately. It is recommended that a complete

assembly be installed rather than placing a new valve in a used seat.
5. Keep the suction and discharge manifold bolting tight.*
4.3 Removal
• Remove the valve cover, gasket, and the valve spring. The upper valve stem guide is bolted
to the cover and is removed with the valve cover.
• Lift out the valve assembly.
• Using a valve seat puller, remove the valve seat. NEVER USE A CUTTING TORCH TO
REMOVE A VALVE SEAT.
4.4 Installation
i. Carefully clean and inspect all parts for damage, defects and wear – replace if necessary.
Any damage or fluid cuts in the valve seat bores must be repaired before installing new valve
seats.
ii. Thoroughly clean the valve seats and the valve seat bores using non-toxic, non-explosive
mineral spirits or commercial solvents. If it is necessary to polish these surfaces, use fine
emery cloth and re-clean. Dry the seat and the seat bores with an air hose – DO NOT
LUBRICATE.
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iii. Place the valve seat in the valve seat bore and place the valve cover in the seat. Place a
short length of large diameter, heavy wall pipe over the upper valve stem, and using a
sledgehammer to strike the pipe, drive the valve seat into place. The seat should be firmly in
place when the pipe bounces free with each blow from the sledgehammer.
iv. Install the valve spring. Use a new spring with each new valve body.
v. Thoroughly clean the gasket surface and threads on the valve cover, and in the valve
chamber. Repair any damage found on the gasket surfaces. Lubricate a new gasket with a
light coating of grease and place it in the counterbore of the fluid chamber.
vi. Apply a liberal amount of a good quality anti-seize compound on the threads of the valve
cover and the threads in the fluid end segment. Install the valve cover. Be certain that the
valve spring is in place and that the upper valve guide bushing is over the valve stem.
vii. Tighten the screw type valve cover by placing a heavy bar in the holes provided and bumping
the bar if necessary. Never pound directly on the valve cover.
5 PISTONS AND LINERS
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The pistons and liners in a reciprocating pump are subjected to severe conditions which
promote rapid wear; proper maintenance and replacement parts of highest quality are
necessary to extend the service life of these components. The piston assemblies are API
type SA-4 and the liners are SUPER DI-HARD.
1. Piston Rod Nut

2. Retaining Plate
3. Piston Rubber
4. Piston Body
5. O-Ring
6. Piston Rod
7. Wear Plate Gasket
8. Liner Wear Plate
9. Liner Gasket
10. Liner Adapter
11. Fluid Cylinder Liner
12. Liner Retaining Nut
13. Liner Flushing Shield
14. Piston Rod Extension
15. Extension Rod Clamp
16. Crosshead Extension
5.1 General
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The pump is normally shipped with the pistons unassembled. Refer to INSTALLATION
instructions which follow for detailed assembly.
The API SA-4 piston rod has been provided with an extension to facilitate removal of the
piston/piston rod assembly. Both of these parts are phosphate coated for protection
against corrosion.
5.2 Maintenance
- Keep liner, piston, piston rod and piston rod extension tightly in position.*
- Keep the liner flushing system flowing at the proper rate filled with the proper fluid
and free of contamination.
- Replace worn or deteriorated piston assemblies immediately.
- Maintain liners in good condition or replace to prevent piston failures.
- Replace liner gasket if leak is detected and each time a liner is installed.
- Replace the piston rod nut if damaged or if seal is deteriorated.
- Use only a box wrench on the piston rod nut (a pipe wrench will squeeze the nut
causing distortion and incorrect torquing value).
5.3 Removal
• Disconnect the pump from its power source.
• Manually rotate the pump sheave or flexible coupling on the pump pinion shaft or the manual
turning device to bring the extension rod clamp and extension rod into the most accessible
position.
• Remove the extension rod clamp.
• Remove the liner flushing shield. It may be necessary to rotate the pump pinion shaft to
provide clearance between the crosshead extension rod and the piston rod for removal of the
shield.
• Unscrew the piston rod extension from the piston rod using two open end wrenches on the
wrench flats.
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• Place the open end of the piston rod “tool” on the button end on the crosshead extension and
rotate the countershaft to engage the threads on the other end of the tool with the threads on
the piston rod. Screw the tool onto the piston rod.
• Rotate the pump countershaft to withdraw the piston/piston rod assembly from the liner.
• The three dog point set screws in the liner nut should be adjusted to place the dog of the
screw well inside the groove of the liner, but not jammed or set in the bottom of the groove.
Place a brass bar on one of the lugs on the liner nut and strike the brass bar with a
sledgehammer to unscrew the nut which in turn will, with the setscrews riding inside the liner
groove, withdraw the liner from the fluid chamber.
• Remove the setscrews from the liner nut, then remove the liner nut and the liner with its gasket
from the pump.
• Protect the threaded end of the piston/piston rod assembly and place the assembly in the
“back-up” tool located at the rear of the pump skid. Using a box wrench, unscrew the piston
rod nut and remove the component parts of the piston assembly.
5.4 Installation
7. Carefully clean and inspect all parts for damage, defects and wear – replace if
necessary.
8. Clean the surface of the liner wear plate. If corrosion or wear damage is present,
replace the wear plate and wear plate gasket.
9. Remove any paint and polish the O.D. of the liner, place the liner gasket on the liner
and place the liner inside the liner adapter.
10. Using a good quality multi-purpose grease, lubricate the exposed portion of the liner,
the threads on the liner adapter and the inner surface (including internal threads) of the
liner nut.
11. Remove the setscrews from the liner nut and screw the nut onto the liner adapter.
When the nut is tight place a brass bar against one of the lugs and striking the brass
bar with a sledgehammer, continue to tighten the nut until firm metal-to-metal contact is
achieved between the liner wear plate, the liner and the liner nut.
12. Check the inner bore of the liner to be certain that the liner gasket has not become
misplaced during installation.
13. Replace the setscrews in the liner nut, but do not tighten these against the liner (the
setscrews are used only at the time of liner removal).
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14. Make the piston/piston rod assembly by placing the piston rod in a vise with the piston
end of the rod in the top vertical position and install the following on the rod in
sequence:
14.1. “O” Ring

14.2. Piston Body
14.3. Piston Rubber
14.4. Retaining Plate
14.5. Piston Rod Nut
Tighten the piston rod nut by protecting the threaded end of the rod against damage
and placing it in the “back-up” tool at the rear of the pump skid and torquing the nut with
a box wrench.*
15. Lubricate the piston with a light coating of grease or oil, and screw the piston rod “tool”
on the end of the piston rod. Place the open end of the piston rod “tool” over the button
end of the crosshead extension, align the piston with the bore of the liner, then rotate
the pump countershaft to force the piston into the liner. Exercise care during the
installation to prevent damage or “roll-back” of the piston rubber lips.
16. Remove the piston rod “tool” and install the piston rod extension. Use two open end
wrenches to tighten the piston rod extension on the piston rod.*
17. Install the liner flushing shield.
18. Install the extension rod clamp.*
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6 POWER END
The power end of the pump is comprised of the sub-assemblies as listed below plus a
lubrication system. Each sub-assembly and the lubrication system is subsequently detailed
in this publication.
1. Power Frame
2. Diaphragm Assembly
3. Crosshead Assembly
4. Connecting Rod Assembly
5. Crankshaft Assembly
6. Countershaft Assembly
(optional) *
7. Gear Reduction Unit *
*Not illustrated
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6.1 General
The power end of the pump is designed with access covers and doors of maximum size
consistent with servicing requirements plus retaining rigidity and strength of the power
frame.
Specific instructions for the removal and re-installation of each sub-assembly are detailed
in the continuing text.
6.2 Maintenance
To prevent the necessity of removing the subassemblies because of improper care, it is

recommended that the minimum maintenance program outlined in the OPERATORS
MANUAL be initiated, and if necessary expanded to meet specific requirements.
6.3 Removal
• To remove the power end of the pump requires hoisting equipment with capacity for the
safe handling of the weight.
• Separate the pump from its power source and remove the drive arrangement, i.e., the drive
guard, sheaves, sprockets, couplings, etc.
• Remove the fluid chambers. Refer to FLUID CHAMBERS in this publication for specific
instructions.
• Drain the liner flushing system. Drain the lubricating oil, including the sludge in the trap.
• Disconnect base mounted drain lines and lubrication lines. Disconnect all electric lines to
pump safety switches.
• If shear blocks have not been welded on the base apply these at this time in order that the
power end can be returned to the base and aligned to its original position. For welding
instructions refer to the APPENDIX of this publication.
• Remove the hold-down capscrews at the base of the pump power frame and lift the power
end from the steel base. Do not attach hoisting lines or pick-up lines to the pinion shaft or
across any machined surface of the power frame.
6.4 Installation
• Be certain that the steel base is clean and level, then place the power end on the base.
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• Install the hold-down capscrews, but do not tighten it.

• Connect the drain lines and lubrication lines to the power frame. Connect safety switches.
• Install the fluid chambers. For instructions refer to FLUID CHAMBERS in this publication.
• Install the drive arrangement and align the prime mover(s) with the pump. Instructions for
alignment are contained in the OPERATORS MANUAL which accompanied the shipment of
this pump.
• Tighten the hold-down bolts.*
• Recheck the alignment of the unit and adjust if necessary. Secure the alignment.
• Replace guards, safety railings, etc.
• Fill the crankcase and liner flushing reservoir as outlined in the OPERATORS MANUAL,
and be guided by other instructions detailed under PREPARING FOR OPERATION and
PLACING IN OPERATION in the OPERATORS MANUAL.
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7 DIAPHRAGM ASSEMBLY
The diaphragm is a dual purpose assembly designed to (1), keep the lubricating oil in the
crankcase and (2), keep foreign material that collects on the crosshead extension rod from
entering the crankcase and contaminating the lubricant.
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7.1 General
This is a relatively simple assembly, but is most important in preserving the quantity and
condition of the lubricant.
7.2 Maintenance
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• Be certain that the diaphragm supports are properly indexed in the power frame. These
supports are numbered and a matching number is in the power frame adjacent to the
number on the support.
• Keep the diaphragm supports, the diaphragm housings and diaphragm glands securely in
place.*
• Keep the vent holes and drain holes free of obstructions.
• Should leakage occur, replace the wiper rings immediately. Replace the crosshead
extension rod if necessary.
• Should some failure occur at the fluid end of the pump which causes the pumped fluid to
“blast” the diaphragm area or flood the cradle section of the pump, immediately remove the
pump from service and change the lubricant in the pump.
7.3 Removal
1. Remove the extension rod clamp. Refer to PISTONS AND LINERS in this publication
for instructions.
2. Continue to rotate the shaft assemblies to separate the end of the crosshead extension
from the piston rod extensions.
3. Remove the capscrews from the diaphragm housing assembly and slip the assembly
removed from the pump, separate the assembly by removing the diaphragm cover, the
wiper rings, the lantern rings, etc.
7.4 Installation
• Carefully clean and inspect all arts for damage and wear. Replace damaged and worn
parts.
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• Refer to the sketch to the left of this page and assemble the components as indicated
and tighten* the lock nuts which retain the diaphragm gland. Be certain the sealing lips on
the wiper rings are properly indexed and that the drain holes in the housing glands are
adjacent to each other at the bottom of the assembly.
• With the proper assembly having been made, loosen the lock nuts retaining the gland,
remove the gland, coat the crosshead extension rod with a light lubricant, slide the gland
assembly with its gasket over the end of the extension rod and into its operating position.
• Secure* the diaphragm housing to the diaphragm support and the gland to the housing.
• Observe the foregoing instructions to install the other diaphragm assemblies.
• Install the extension rod clamps. Refer to PISTONS AND LINERS in this publication for
specific instructions.
8 CRANKSHAFT ASSEMBLY
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During operations the crankshaft in the pump is generally heavily loaded and under this
condition requires the protection of continuous lubrication and the immediate replacement
of worn or damaged main bearings, crankpin bearings, retainers, etc. When servicing is
necessary, it can be most efficiently performed if the pump is removed to an area were an
overhead crane, hydraulic press, bearing pullers and other industrial tools are accessible.
8.1 General
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The crankshaft is mounted in two intermediate and two main bearings. The intermediate
bearings are of the straight roller type and the main bearings are of the tapered roller type.
8.2 Maintenance
Be sure that the lubricating oil is properly maintained and that the oil level in the crankcase
is always between the “high” and “low” points on the oil level dip stick.
Keep the bearing housing and the bearing retainer capscrews tight.*
Keep the lateral movement (or end play) of the crankshaft within the range from .000”
(.000mm) to .002” (.0508mm). CAUTION: Be certain there is no pre-loading of the main
bearings if the lateral movement is .000” (.000mm).
Make frequent checks on the crankpin bearing wear (refer to CONNECTING RODS in this
publication for details).
8.3 Removal
Separate the pump from its power source and provide a suitable work area at the side of the
pump for removal of the shaft. NOTE: The shaft can be removed from either side of the pump.
Drain the oil from the crankcase and drain the sludge trap.
Remove the drive arrangement or if the pump is so equipped, remove the rear reduction unit
(refer to GEAR REDUCTION UNIT in this publication for details relative to the removal of the gear
unit).
Remove the frame end plate with its gasket.
Rotate the crankshaft to move on of the extension rod clamps as far as possible forward in the
cradle section of the pump. Remove the clamp from this extension rod and remove the extension
rod. Repeat these instructions until the other clamps and extension rods are removed from the
unit.
Loosen the fasteners retaining the diaphragm supports and move the diaphragm assemblies
forward on the crosshead extension rods.
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Remove the cotter pins, nuts, bolts, oil slingers and caps from the connecting rods. Support the
connecting rods and move them with their respective crossheads as far forward (toward the fluid
end) in the pump as possible.
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Remove the plate, gasket and the attached oil scraper from the top of the power frame.
Remove the countershaft assembly (refer to COUNTERSHAFT ASSEMBLY in this publication for
details relative to the removal of the countershaft assembly).
Remove the main bearing housing cover with its gasket, oil seal, oil pump and drive pinion from
the side of the pump.
Install two round bars (approximately 8” (203.2mm) long with ¾ - 10x2” threads on one end of
each bar) in two of the drilled holes at the top of the main bearing housing. Screw these bars into
the power frame – these are to support the main bearing housing while it is being removed from
the power frame.
Install four ¾ - 10x4” jackscrews in the tapped holes provided in the main bearing
housing – evenly tighten these screws to pull the main bearing housing from the power
frame.
Remove the main bearing housing from the support bars. Remove the jackscrews and
the main bearing housing shims from the bearing housing.
Remove the capscrews from the main bearing housing on the opposite side of the pump and
follow the instructions outlined in paragraph 11 above to remove this housing.
If the pump is not equipped with a gear reduction unit, two oil seals will be removed with
this bearing housing
NOTE: The cups for the main bearings, having been pressed tightly into the main
bearing housing, are normally removed with the main bearing housings.
The crankshaft can now be pressed or pulled from the power frame. It is to be remove in the
direction which permits the lubrication ring, installed on the crankshaft to be moved through the
side of the power frame adjacent to its installed position.
Careful axial alignment of the crankshaft and the power frame must be maintained to
permit the cage and roller assembly of one intermediate bearing to pass through the
outer race of the other intermediate bearing.
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With the crankshaft supported by wooden “V” blocks on a work table proceed to remove the
following:
Oil pump drive gear
Crankshaft key
Main bearings (both sides)
Lubrication Ring
Lubrication Ring Retainer
Intermediate bearing retainers & slims
Intermediate bearings
Crankshaft spacer
Using a circular steel plate (approximately 19½” O.D.) [495.3mm] and a puller bar, remove the
outer races for the intermediate bearings from the power frame. Refer to the sketch on the
opposite page and note that the races are flanged on the O.D. and can be removed only in one
respective direction.
Use a bearing puller to pull the cups for the main bearings from the main bearing housing.
8.4 Installation
Carefully clean and inspect all parts for damage and wear – replace all parts damaged and worn
Place the following parts in a vat containing 15% soluble oil in water and heat to approximately
200°F (93 C.).
Crankshaft spacer
Inner race and rollers for both intermediate bearings
Inner race and rollers for both main bearings
Support the crankshaft with wooden “V” blocks on a work table and observe the sketch on the
opposite page to determine the installed position of the parts comprising the crankshaft assembly.
Using wire hooks or tongs and heat resistant gloves, remove the intermediate bearing inner race
and roller assemblies from the heated oil/water solution and place them on the shaft. Be certain
that the inner race is firmly against the flange on the crankshaft bearing surface and that each is
held in this position until it cools and grips the shaft.
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Install the intermediate bearing retainer and shim set on the intermediate bearing most remote to
the “drive end” of the crankshaft. Add or remove shims to obtain not more than .005” (.127mm)
interference clamping of the retainer against the inner race of the bearing.* Install the locking
wire.
Install the intermediate bearing retainer, shim set and lubrication ring retainer on the intermediate
bearing adjacent to the “drive end” of the crank shaft. Add or remove shims to obtain not more
than .005” (.127mm) interference clamping of the retainer against the inner race of the bearing.*
Install the locking wire.
Install the lubrication ring with the extended portion of the flange extended over the
retainer toward the bearing.* Install the locking wire.
EXCEPTIONS TO PARAGRAPHS 5 and 6 ABOVE

Some units have been equipped with two lubrication rings (one on each of the
intermediate bearings) and in some instances the lubrication ring will not pass through
the outer races for the intermediate bearings when they are installed in the power
frame.
When this situation is encountered it is suggested that the instructions in paragraph 5

be observed except the lubrication ring retainer should be installed with the bearing
retainer (do not install the lubrication ring at this time). Observe the instructions
contained in paragraph 6, and then install and tighten* the second lubrication ring after
the crankshaft has been placed in the power frame, and prior to the installation of the
main bearing housings.
Individually remove the inner race and roller assemblies (cones) for the main bearings from the
heated oil/water solution and place these on the crankshaft. Refer to the sketch on the opposite
page and be certain that these portions of the bearings are properly indexed, hold them firmly
against the shoulder on the shaft until they cool and grip the shaft.
Install the heated crankshaft spacer properly indexed on the shaft, hold it firmly against the
shoulder until it cools and grips the shaft.
Press the outer races from the intermediate bearing into the power frame. The steel plate and
puller bar which was used to remove these races can be placed on the opposite side of the pump
to pull these races squarely and firmly into position.
Press the outer races (cups) for the main bearings, properly indexed into the main bearing
housings. Be certain that they are in full circumferential metal-to-metal contact with the shoulder
inside each bearing housing.
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Carefully support the crankshaft with the assembled bearings and retainers: move it properly
indexed through the opening on the “drive side” of the power frame. Round or hexagonal steel
bars, threaded one end, engaged with the tapped openings at each end of the crankshaft will aid
in balancing and guiding the assembly into the power frame. NOTE: The axis of the crankshaft
must be on the same axis as the openings in the power end because the cage and roller
assembly of one intermediate bearing must pass through the outer race of the other intermediate
bearing.
Make temporary installation of the main bearing housing (oil pump side) and shim set. Add or
remove shims as necessary to align the inner and outer races of the intermediate bearings on a
vertical axis.
When this alignment has been effected, make the final installation of this bearing
housing with the application of the housing cover with gasket, the oil pump with its drive
pinion, the oil seal with sealing lip outward and the auxiliary drive sheave.
Make temporary installation of the main bearing housing (drive side) – do not tighten the
capscrews. Use feeler gauges to determine the “gap” between the power frame and the flange on
the housing. Remove the housing and reinstall, using enough shims to fill this “gap” plus an
additional.005” (.127mm) shim (or lamination). Tighten* the capscrews, and use a dial indicator to
determine the lateral movement or “end play” in the crankshaft. The “end play” should be slightly
less than .005”” (.127mm), and this must be reduced by removing shims until it is .000’ (.000mm)
to .002” (.508mm).
NOTE: It is suggested that a piece of dimensioned hard wood be inserted through the
rear frame opening with the top of the inner end in contact with the crankshaft, and that
this is to be used as a “pry bar” to move the crankshaft on its horizontal axis (to obtain
the dial indicator readings of later movement or “end play”). Be certain that the shaft or
the power frame is not damaged or distorted.
CAUTION: During and after final bearing adjustment the crankshaft must be free to
rotate unrestricted. There must be no pre-loading of the bearings because such
imposed forces can result in bearing failure within a very few revolutions. When the
crankshaft is mounted in properly adjusted bearings it can be rotated manually by
gripping the extended portion of the shaft with your hands and turning it 360 degrees (or
more) in both directions.
Install the heated crankshaft spacer on the crankshaft. Be certain that it is properly indexed and
that it is held firmly against the shoulder on the shaft until it cools and grips the shaft.
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Install the oil seals in the main bearing housing (drive side). The sealing lip of the inside oil seal
should be in the direction of the bearings and the sealing lip of the outside oil seal should be in the
direction of drive end of the shaft.
Install the crankshaft key.
If the unit is equipped with a mechanically integrated gear reduction, reinstall the gear unit. Refer
to GEAR REDUCTION UNIT in this publication for specific instructions.
Install the countershaft assembly. Refer to COUNTERSHAFT ASSEMBLY in this

publication for specific instructions.
Install the caps, oil slingers, etc., on the connecting rods. Refer to CONNECTING RODS in this
publication for specific instructions.
Move and fasten* the diaphragm assemblies into their proper position. Refer to DIAPHRAGM
ASSEMBLY for specific instructions.
Assemble the drive arrangement which was removed at the commencement of unit disassembly.
Replace all drain plugs or otherwise close all lubricating oil drains. Lubricate the unit – refer to
LUBRICATION INSTRUCTIONS in the OPERATORS MANUAL for specific instructions.
Refer to and be guided by the instructions under the subjects of PREPARING FOR
OPERATIONS and PLACING IN OPERATION which are printed in the OWNERS MANUAL
prepared for this unit.
9 CROSSHEADS
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The crossheads stabilize the vertical movement, and to some degree the horizontal
movement of the pump end of the piston rod during the reciprocating cycle; therefore,
alignment is critical to the proper function of the diaphragm, true axial movement of the
piston and concentricity of the piston in the liner.
9.1 General
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The crossheads are heavily constructed, fitted with upper and lower shoes and operate in
removable upper and lower guides. Both the shoes and guides are replaceable and are
shim adjustable. Correct crankshaft rotation is important to the service life of the crosshead
assembly, the force transferred from the crankshaft to the crosshead should be above the
horizontal center-line of the crosshead. This allows the crosshead to reciprocate in the
lower guide and it is not being lifted to the upper guide during the power stroke and then
falling to the lower guide and the reversal point.
9.2 Maintenance
Maintain lubrication consistant with the instructions outlined under LUBRICATION in this
publication.
As a MINIMUM check the clearance of the crosshead pin bushings and the crossheads every six
months (more often if they reflect excessive wear, high temperature or are noisy).
Cross Pin: Bushing

.006” (.1524mm) - .008” (.2032mm)
Crosshead: Crosshead Guide

0.12” (.3048mm) - .016: (.4064mm)
Crosshead Pin: Crosshead

(Tapered interference fit)
Keep the crosshead pin retaining plate tight* against the crosshead pin. Do not permit the pin to
become lose or to rotate in the crosshead
Keep the crosshead shoes and crosshead guides very securely in position.
Keep inspection doors and covers in place to prevent foreign material from collecting on the
wearing surfaces.
9.3 Removal
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Separate the pump from its power source and provide a suitable work area at the sides of the
pump.
Remove the side covers and rear frame cover (with gaskets) from the pump.
Remove the liner flushing connections, and shields (if the pump is so equipped).
Rotate the shaft assemblies to move one of the pistons forward in the liner to the point where only
the wrench flats on the piston rod protrudes from the liner.
Remove the extension rod clamp and the piston rod extension from this assembly.
Remove the other two clamps and piston rod extensions by observing the instructions outlined in
the foregoing paragraph.
Removal of the liner retaining nuts will provide additional clearance for the removal of the
components and sub-assemblies comprising the crossheads and crosshead guides.
Loosen the diaphragm glands to relieve the pressure on the wiper rings, then remove the nuts
from the diaphragm supports. Slide the diaphragm/support assemblies over the end of the
crosshead extension rods, and lift them and the support gaskets from the pump. NOTE: These
assemblies are numbered and must be reinstalled in the same position from which they were
removed.
Cut the locking wire and remove the crosshead extension rods and oil baffles from the front of the
crossheads.
Working from the side of the pump which is opposite to the gear reduction unit, cut the locking
wire and remove the crosshead pin retaining plate.
Rotate the crankshaft to move this crosshead assembly as far forward as possible in the
pump. Use wooden blocks to support the crosshead end of the connecting rod, and
then pull the crosshead pin.
With the crosshead pin removed, the crosshead can be moved forward through the
opening vacated by the diaphragm assemblies and lifted from the pump.
Follow the instructions outlined in the foregoing paragraph to remove the center crosshead, and
then the crosshead adjacent to the gear reduction unit. CAUTION: Do not let the connecting rods
drop and ride on the lower crosshead guides.
Remove the upper and lower shoes and if installed, the shim sets from the crossheads.
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Cut the locking wire and remove the clamps, spherical washers, lower crosshead guides, upper
crosshead guides and shims from the power frame.
9.4 Installation
The crossheads must reciprocate on an axis horizontal to the center line of the crankshaft.
They must travel on a true plane without horizontal or vertical deviation. Proper installation
and maintenance is necessary to prevent the development of destructive forces and
stresses.
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Carefully clean and inspect all parts for flaws, defects and wear. Replace all parts that are
obviously defective and all that are of questionable quality.
Using crosshead guide clamps and spherical washers, install and tighten* the upper and lower
crosshead guides in the power frame adjacent to the gear reduction unit.
Use an inside micrometer to be certain that these installed guides form a true cylinder.
If the bore, thus formed is larger at one end than it is at the other end, add shims (equal
amounts to the top and bottom) at the end with the larger bore to reduce this bore and
make it equal to the bore at the opposite end.
Follow the instructions outlined in the foregoing paragraph to install the remaining guides.
Use a straight edge or chalk line to align the edges of the upper guides and the lower guides. The
alignment should extend across the pump frame at both the forward and rear positions. It may be
necessary to loosen and re-tighten the clamping capscrews to achieve this alignment.
When the proper alignment and “bores” have been obtained (the clamping capscrews
should be fully torqued*) install the locking wire.
Install the upper and lower shoes on the crossheads.
Lubricate the upper and lower guides for the crosshead adjacent to the gear reduction unit. Insert
one of the crossheads in this set of guides (the connecting rods should be supported on wooden
blocks to center the eye of the rods to the center of the guides). Move the crosshead forward and
backward to be certain that it is not binding.
Install the crosshead extension rod on this crosshead – tighten the capscrews.*
Install the diaphragm support – be sure this is the support removed from this position.
Also, the diaphragm housing, gland, rings, etc., must be removed from the support prior
to this installation.
Use a telescoping gauge and outside micrometer to determine the position of the
crosshead extension rod inside the opening of the diaphragm support. Take readings
with the crosshead in the forward, center and back positions. If the guides were
properly installed the readings should be the same in all three positions, if not, recheck
the installation – refer to the foregoing paragraphs 2, 3 and 4 for detailed instructions.
NOTE: The design of these assemblies permits the center of the crosshead extension
rod to be in the lower portion of the diaphragm support opening (at this stage of the
installation). Make notes of the micrometer readings.
From the micrometer readings obtained when the guides were installed and those obtained in the
foregoing, calculate:
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The thickness of shims required between the crosshead and the lower shoe to bring the extension
rod up into the center of the opening in the diaphragm support.
The thickness of shims required (if any) between the crosshead and the upper shoe provide .012
(.2048mm) - .016” (.4064mm) clearance between the top of the upper shoe and the upper
crosshead guide.
Remove the crosshead (instructions appear earlier in this section) and install the
required shims.
Re-install the crosshead, crosshead extension rod and diaphragm support (instructions outlined in
foregoing paragraphs 6 and 7).
Move the crosshead forward and backward in the guides to be certain that it is free and
travels unrestricted.
Repeat the gauging as outlined in paragraph 7 to be certain that the extension rod is in
the center of the opening in the diaphragm support.
With the crosshead alternately in the forward, center and backward positions, insert
long feeler gauges between the upper crosshead shoe and the upper crosshead guide.
The feller gauges must go completely over the upper shoe and extend beyond the
guide on the opposite side. The gauges must be inserted at the center and at both
ends of the crosshead when it is in all three of the above positions. The clearance must
be at all points between .012” (.3045mm) and .016” (.4064mm).
Install the oil baffle on the crosshead extension rod, tighten all the capscrews* and retain with
locking wire.
Support the connecting rod at the “eye” end, center the “eye” in the crosshead and install the
crosshead pin. Strike the large end of the pin with a heavy plastic mallet to seat it in the taper of
the crosshead and install the crosshead pin retaining plate, capscrews* and locking wire. NOTE:
The retaining plate is installed to cover the half of the pin adjacent to the crankshaft.
Install the diaphragm housing, rings, etc. Refer to DIAPHRAGM ASSEMBLY in this publication
for specific instructions.
Observe the instructions outlined in the foregoing paragraphs 6 thru 12 to install the center
crosshead, and then the crosshead opposite the gear reduction unit.
Install the liner retaining nuts, the piston rod extensions and the extension rod clamps. Refer to
PISTONS AND LINERS in this publication for detailed instructions.
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Install the liner flushing connections and shields; the side covers and the rear frame cover with
their respective gaskets.*
Review and be guided by the instructions contained in PREPARING FOR OPERATION and
PLACING IN OPERATION in the OWNERS MANUAL.
10 CONNECTING RODS
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The connecting rods because they have no wearing parts, and are heavily constructed
require very little attention; however, the crankpin bearings, and crosshead pin bushings
contained in the connecting rods will require replacement when excessively worn.
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10.1 General
The connecting rods are marine type (enclosed eye at crosshead end, and with separate
cap the crankend). They are ridgid in construction and designed to accept replaceable
parts at the wear points, i.e., bearing at the crankend and bushings at the crosshead end.
10.2 Maintenance
6. Be sure that the lubrication system is properly maintained to insure lubrication of the
crankpin bearing and crosshead pin bushing.
7. As a MINIMUM, check the crankpin bearing and crosshead pin bushing clearance
every six months (more often if they are noisy or reflect excessive temperature).
8. Normal running diametrical clearance should be maintained as follows:
8.1 Crosshead Pin Bushing:

.006” (.1524mm) - .008” (.2032mm)
8.2 Crankpin Bearing:

.004” (.1016mm) - .009” (.2286mm)
9. Anytime the cap is removed from a connecting rod, be certain that it is replaced on
that same rod in the same relative position (the cap and the rod are punched marked for
this identification.
10.3 Removal
Separate the pump from its power source and provide a work area with a minimum of 3 ft.
clearance (from the rear of the pump) for removal of the connecting rods.
Drain the lubricant from the pump. Drain the sludge trap.
Remove the side covers and rear frame cover with their respective gaskets from the pump frame.
Remove the iner flushing connections and shields (if the pump is so equipped).
Rotate the shaft assemblies to move one of the pistons forward in the liner to the point wher only
the wrench flats on the piston rod protrudes from the liner.
Remove the extension rod clamp and the piston rod extension from this assembly.
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Remove the other two clamps and piston rod extensions by observing the instructions outlined in
the foregoing paragraph.
The diaphragm supports in front of the crosshead assemblies “A” and “B” must be removed to
permit the crossheads to move forward into the cradle section of the pump.
Loosen the diaphragm glands to relieve the pressure on the wiper rings, then remove
the nuts from the diaphragm supports. Slide the diaphragm supports assemblies over
the end of the crosshead extension rods and lift them and the support gaskets from the
pump. NOTE: These assemblies are numbered and must be reinstalled in the same
position from which they were removed.
Rotate the crankshaft to move crosshead assembly “A” as far forward as possible in the pump.
Use wooden blocks to support the crosshead end of the connecting rod, then cut the
locking wire and remove the crosshead pin retaining the plate. Pull the crosshead pin.
With the crosshead pin removed, the crosshead can be moved forward through the
opening vacated by the diaphragm assembly.
Follow the instructions outlined in the foregoing paragraph to remove crosshead assembly “B”,
NOTE: Support the connecting rods at all times to prevent them from falling or riding on the lower
crosshead guides.
Cut the locking wire, remove the crosshead pin retaining plate and pull the pin from crosshead
assembly “C”.
With the connecting rod for crosshead assembly “A” as far forward as possible in the pump,
support the connecting rod, then remove the cotter pins, nuts, oil slinger, bolts and cap from the
crankend of the connecting rod.
Rotate the crankshaft slowly, by hand to lower the crankend of the connecting rod and
continue to rotate until the crankpin is in an elevated position, then pull the connecting
rod through the rear opening in the power frame.
Follow the instructions outlined in the foregoing paragraph to remove the remaining connecting
rods.
Remove the crankpin bearing (two halves) from the connecting rod and connecting rod cap.
Press the crosshead pin bushings from the connecting rods.
10.4 Installation
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Press the crosshead pin bushings into the connecting rods. This should be a .001” (.0254mm) to
.003” (.0762mm) interference fit. After the bushing is in place, slide the crosshead pin into the
bushing and gauge the clearance – the clearance should be .006: (.1524mm) to .008” (.2032mm),
if the pin is tight in the bushing, hone the bushing if the clearance is in excess of .008” (.2032mm),
select another crosshead pin or renew the bushing.
Fit the crankpin bearings one-half in the connecting rod and one-half in the connecting rod cap.
These are guided by slots in the rod and in the cap. NOTE: Observe item No. 4 under
maintenance for the assembly of the cap with the rod.
Slide the connecting rod for crosshead “C” into position inside the pump and rotate the crankshaft
until it engages the inner surface of the bearing insert. Fit the connecting rod bolts into the
connecting rod.
Select the matching cap to this particular connecting rod and place “plasti-gauge” or .015”
(.381mm) resin core solder across the inner bearing surface as close as possible to the dowel port
in the bearing insert. Fit the cap on the bolts, lubricate the bolt threads, install the nuts and tighten
with 236 ft/lb torque. Remove the connecting rod cap and determine from the plasti-gauge scale
or by “miking” the solder, if the crankpin bearing clearance is between .004” (.1016mm) and .009”
(.2286mm), proceed to the next step in these instructions, if not replace the bearing, and repeat
the gauging procedure.
Install the cotter pins in the connecting rod cap bolts.
Lubricate the upper and lower guides for all of the crossheads.
Support the connecting rod at the “eye” end, center the “eye” in the crosshead and
install the crosshead pin. Strike the large end of the pin with a heavy plastic mallet to
seat it in the taper of the crosshead and install the crosshead pin retaining plate,
capscrews* and locking wire. NOTE: The retaining plate is installed to cover the half of
the crosshead pin adjacent to the pump crankshaft.

Place crosshead assembly “B” in its guides, install the connecting rod and crosshead pin for this
assembly as outlined in the foregoing paragraph.
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Follow these same instructions to install the crosshead, connecting rod, and pin for
assembly “A”.
Rotate the crankshaft by hand to be sure it can rotate freely and unrestricted.
Install the diaphragm supports (these are numbered and must be installed in the same position
from which they were removed), and the diaphragm assemblies. Refer to DIAPHRAGM
ASSEMBLY in this publication for specific instructions.
Install the piston rod extensions and clamps. Refer to PISTONS AND LINERS in this publication
for detailed instructions.
Install the liner flushing connections and shields; the side covers and the rear frame cover with
their respective gaskets.
Close the drains and fill the power end with lubricant as directed, and specified in the LUBRICAN
TABLE published in the OWNERS MANUAL.
Review and be guided by the instructions contained in PREPARING FOR OPERATION and
PLACING IN OPERATION published in the OWNERS MANUAL.
11 GEAR UNIT
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These speed reducers with single helical gears are designed for mechanical integration on
either the right hand or left hand side of the power end. Also, they may be omitted from the
pump if it is practical to apply power directly to the pump crankshaft.
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11.1 General
The gear unit, as with many products of the industry has numerous names. These
assemblies may be referred to as “gear reducer”, “gear box”, “speed reducer”, “the gears”,
“bull gear and pinion”, etc. The product detailed to the left of this page has been designed
in different reduction ratios to limit the crankshaft speed at approximately 175 rpm when the
maximum driving power is applied to the pinion shaft.
11.2 Maintenance
Be sure that the unit is properly lubricated at all times, that the lubricant is free of contamination
and that it is between the “high” and “low” marks on the oil level dipstick when the unit is idle.
Keep all fasteners properly torqued* and where indicated, securely locked in place.
Keep the air breather clean.
11.3 Removal
Separate the pump from its power source and remove the sheave or coupling from the pinion
shaft.
Drain the lubricant from the gear case and remove the oil level piping. Install a pipe plug in the
drain opening.
Remove the lubricant return line between the gear case and the crankcase on the pump.
Remove the air breather.

Remove the capscrews and hex nuts holding the pinion bearing housing to the gear case.
Support the pinion shaft and carefully remove it as an assembly, from the gear case.
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With the pinion shaft assembly properly supported on a work bench remove the
following from the shaft:
Pinion Shaft Key

Housing Cover with Oil Seal
Housing Cover Gasket
Shim Set
Place the remaining portion of the assembly in a hydraulic press with the support plate or bar
between the bearing housing and the pinion. Center the ram of the press on the outer face of the
pinion shaft and apply force sufficient to press the shaft from the spherical roller bearing and the
bearing spacer or wear sleeve.
Use a bearing puller to remove the inner race for the straight roller bearing from the
shaft.
Remove the pinion bearing cover (closed side) and gasket from the gear case.
Use a bearing puller to remove the outer race and roller assembly for the straight roller
bearing from the gear case.
Remove the capscrews holding the outer cover on the gear case. NOTE: If the pump is equipped
with gear case supports, these should be removed at this time.
Remove the gear case cover with the bearing cover, bearing cover gasket and outer
race and roller assembly for the crankshaft bearing from the gear case.
Remove the bearing cover and bearing cover gasket from the gear case cover.
Use a bearing puller or hydraulic press to remove the outer race and roller assembly
from the gear case cover.
Remove the jam nut from the stud bolt in the end of the crankshaft.
Remove the bearing retainer and use a bearing puller to remove the inner race from the
crankshaft extension.
Cut the locking wire from the capscrews retaining the crankshaft extension, remove the
capscrews and the crankshaft extension.
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Remove the stud bolt from the end of the crankshaft. NOTE: This bolt was installed
with a sealant and more than normal torque may be required for its removal.
Carefully support and remove the crankshaft gear from the crankshaft. If the gear cannot be
manually pulled from the shaft, use a wheel puller or bearing puller for this purpose.
Remove the crankshaft key.
Remove the frame end plate with its gasket from the rear of the pump crankcase.
Locate and remove the eight capscrews and lock washers on the vertical wall of the
crankcase adjacent to the mounted gear case. NOTE: It may be necessary to rotate
the crankshaft at 45 deg. Intervals to expose the capscrews and provide space for their
removal.
Carefully support the gear case. Cut the locking wire from the capscrews retaining the gear case
to the pump crankcase.
Remove these capscrews and the gear case with its gasket should be free to be lifted
from the unit.
11.4 Installation
Carefully clean and inspect all parts for damage and wear – replace all parts damaged and worn.
Place the following parts in a vat containing 15% soluble oil in water and heat to 200º F. (93C.).
Spherical roller bearing

Inner race for pinion bearing
Inner race for crankshaft bearing
Wear sleeve
Install the outer race and roller assembly for the pinion bearing in the gear case. The design
tolerances permit a diametrical clearance of .0007” (.01778mm) ranging to an interference of
.0006”, (.01524mm) in which case it may be necessary to use a hydraulic press to make the
installation.
Install the outer race and roller assembly for the crankshaft bearing in the gear case cover. The
design tolerances here are the same as those listed in the foregoing paragraph.
Position the gear case with its gasket, properly indexed, on the pump crankcase. Install the drilled
head capscrews inside the gear case (tighten these “snugly”, but do not apply full torque at this
time).
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Install the capscrews and lock washers inside the pump crank case. Tighten* these
alternately from top-to-bottom and form side-to-side to prevent critical stresses from
being introduced into the assembly. NOTE: It may be necessary to rotate the
crankshaft at 45 degrees, intervals to provide space and accessibility for the installation
of these fasteners.
Apply full torque* to the capscrews inside the gear case and install the locking wire.
Install the frame end plate and its gasket.
Install the crankshaft key and place the crankshaft gear (with the tapped holes outward) on the
shaft. The diametrical tolerance here is plus or minus .001” (.0254mm). If the interference is
present it may be necessary to warn (not heat) the entire hub of the gear to a maximum of 200º F.
(93C.), to facilitate the installation.
Be certain that the hub of the gear is firmly against the shoulder on the shaft.
Install the stud bolt in the end of the crankshaft. It is suggested that a liquid sealant be used to
lock this bolt in place.
Remove the inner race for the crankshaft bearing from the heated oil/water solution and place it
on the crankshaft extension. Hold it firmly against the shoulder of the extension until it cools and
grips the shaft.
Place the crankshaft extension on the crankshaft, tighten* the capscrews and install the
locking wire.
Place the bearing retainer on the stud bolt, install and tighten* the jam nut.
Remove the inner race for the straight roller bearing from the heated oil water solution and place it
on the pinion shaft. Hold this race firmly against the shoulder on the shaft until it cools and grips
the shaft.
Remove the spherical roller bearing from the heated oil/water solution and place it on the pinion
shaft. Hold this bearing firmly against the shoulder on the shaft until it cools and grips the shaft.
Remove the bearing spacer (or wear sleeve) from the heated oil/water solution and place it
beveled edge outward on the pinion shaft. Hold this firmly against the spherical bearing until it
cools and grips the shaft.
Use a liquid or semi-solid, non-hardening, gasket material to coat the mating surfaces of the gear
case with the gear case cover.
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Align the outer race and roller assembly of the crankshaft bearing (installed in the gear
case cover) with the inner race (installed on the crankshaft extension) and slide the
crankcase cover, guided by the stud bolts extending from the gear housing, into
position. Install and tighten* the capscrews.
Install the crankshaft bearing cover and gasket. Tighten* the capscrews.
Place the shim set and pinion bearing housing on the stud bolts extending from the gear housing.
Install the hex nuts, but do not tighten these at this time.
Place the pinion wit integral shaft (which has been assembled with the inner race for the straight
roller bearing and the spherical bearing) in the bearing housing and carefully guide the inner
bearing race into the outer race and roller assembly. This may have to be rotated slightly to mesh
the teeth of the pinion with the teeth of the crankshaft gear. NOTE: The spherical bearing fits into
the bearing housing with .0000” (.0000) to .018” (.0457) diametrical clearance – should the
tolerance be at the smaller end of this range it may be necessary to use a plastic mallet to drive
the pinion shaft assembly into place.
Remove the hex nuts which were installed to retain the bearing housing. Place the pinion bearing
housing cover, less the oil seal on the stud bolts and tighten * the hex nuts.
When the nuts have been fully torqued, rotate the pinion shaft several turns to permit
the spherical bearing to locate the shaft on its vertical and horizontal axis.
At this point of the assembly the inner race and the outer race of the straight roller
bearing assembly should be in vertical alignment. NOTE: After this alignment is
achieved there will be “end play” or lateral clearance in the assembly – this is built into
and controlled by the spherical bearing.
Remove the bearing housing cover, install the oil seal (with the sealing lip in the outer position),
reinstall the cover and tighten* the hex nuts.
Install the bearing housing cover and gasket on the straight roller bearing assembly located on the
pinion shaft. Tighten* the capscrews.

Install the air breather, remove the pipe plug from the bottom of the gear case, install the oil level
piping and oil level dip stick. Install the lubricant return line on the side of the gear case.
Install the pinion shaft key and reinstall the sheave or coupling as required to reconnect the unit to
its power source.
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Refer to and be guided by the instructions under the subjects of LUBRICATION, PREPARING
FOR OPERATIONS and PLACING IN OPERATION which are printed in the OWNERS MANUAL
prepared for this unit.
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12 COUNTERSHAFT ASSEMBLY
The countershaft assembly is a “power take-off” to drive auxiliary equipment, i.e., a suction
charging pump, flushing pump, etc.
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12.1 General
The counter shaft assembly is an optional feature and is not furnished unless it is
specifically requested. In this assembly the pinion on the countershaft meshes with the
teeth on the spur gear (mounted on the pump crankshaft) to transmit positive rotating
action outside the power frame to drive devices for the support of lubrication or pumping
systems.
12.2 Maintenance
Keep the assembly firmly in place.*
Keep the oil seal functionable.
Keep the drain tube (located at the bottom of the oil catcher) open and provide for the proper
disposition of the drainage.
Do not permit the drive sheave to rotate on the shaft.
Replace leaking gaskets immediately.
Use only a socket or end-wrench on the hexagonal end of the countershaft (this is the manual
turning device). A pipe wrench or a grip type wrench with serrated jaws will round off the
hexagonal shape of the turning device.
12.3 Removal
• Separate the pump from its power source and provide a suitable work area adjacent
to the countershaft assembly.
• Drain the lubricant from the reservoir at the bottom of the gear case (make proper
disposition of this waste).
• If it is desirable to separate the complete countershaft assembly (less the spur gear
on the end of the crankshaft) from the pump, remove the rotorseal from the rotorseal
adapter, remove the capscrews at the outer flange of the gear case and insert two
jackscrews into the tapped openings in the flange and by tightening these, pull the
assembly from its piloted position on the main bearing housing. Otherwise, proceed with
the disassembly as outlined in the following instructions.
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• Remove the countershaft guard.
Remove the bearing retainer with its gaskets and installed oil seal. Remove the oil seal
from the retainer.
• At this point it may be easily possible to remove the countershaft with its integral
pinion and bearings by manually pulling it from the assembly (the outer race and rollers
from the inboard bearing would, of course remain in the housing). NOTE: This removal is
dependent upon the diametrical tolerance between the I.D. of the bearing bore and the
O.D. of the outboard (spherical roller) bearing. If the countershaft is rigidly retained,
proceed with the following sequential disassembly.
• Remove the capscrews from the outer flange of the gear case and insert two
jackscrews in the tapped openings in the flange and by tightening these, pull the assembly
from its piloted position on the main bearing housing. Remove the gasket. Remove the
jackscrews.
• Place the gear case in a press, with the ram of the press centered on the pinion end
of the countershaft apply sufficient force to move the shaft out of the gear case.
• With the countershaft free of the case, use a bearing puller to remove the bearing
spacer and spherical roller bearing.
• Remove the retaining ring from the pinion end of the countershaft, and then remove
the inner race for the inboard bearing (use a bearing puller if necessary).
• Remove the outer retaining ring, the outer race and roller (for the inboard bearing),
and the inner retaining ring fro the gear case (use a bearing puller, if necessary, to remove
the outer race and rollers).
12.4 Installation
Preparatory to assembly, make a physical examination to determine if the following can be

assembled on the countershaft without the use of thermal expansion, hydraulic pressure or
any other force.
Inner race for inboard bearing.

The spherical roller bearing.
The outboard bearing spacer.
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If these parts will not readily fit on the shaft, place them along with the oil slinger in a vat
containing 15% soluble oil and water, and heat to approximately 200ºF. (93 C.). The
vat should be equipped with a rack to permit each part that is being heated to be
completely surrounded with the oil/water solution.
Install the inside retaining ring for the inboard bearing in the gear case. Install the outer
race and rollers for this bearing, and follow this with the outside retaining ring.
The approximate tolerance for fitting the outer race in the gear case ranges from a
clearance of .0003” (.00762mm) to an interference of .0025” (.0381mm); therefore, a
hydraulic press may be required for this installation.
Install the heated inner race for the inboard bearing on the countershaft, and install the
retaining ring.
Install the outboard (spherical roller) bearing on the countershaft. If this was heated prior to
installation, be certain that it is firmly against the shoulder on the shaft, and that it is held in
place until it cools and grips the shaft.
Install the outboard bearing spacer. Again, if it was heated, be certain that it is precisely
in place against the bearing and that it is held there until it cools and grips the shaft.
Install the gear case with its gasket on the pump power frame.*
Place the countershaft with its installed parts in the gear case and mesh the teeth of the
pinion with the teeth of the spur gear on the crankshaft. If necessary, use the outboard
bearing retainer an the capscrews of the proper length to “pull” the outboard bearing into
the gear case (be certain to alternate the torquing of the capscrews to keep the bearing in
alignment with the bore in the gear case).
Make a temporary installation of the outboard bearing retainer and its inner gasket. Make
certain the slot in the housing aligns with the oil drain in the housing
Install the oil seal, properly indexed in the bearing retainer.
Remove the cap screws which made the temporary installation of the bearing retainer.
Tighten* the capscrews and install the locking wire.
Install the countershaft guard and gasket. Install the rotorseal.
If the drain plug at the bottom of the gear case was removed, be certain that this is
reinstalled.
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Reconnect the pump to its power source.
Refer to and be guided by the instructions under the subjects of LUBRICATION,

PREPARING FOR OPERATIONS, and PLACING IN OPERATION which are printed in the
OWNERS MANUAL prepared for this unit.
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13 LUBRICATION
Proper lubrication is essential to trouble-free performance of all machinery. A film of

lubricant must be provided with sufficient strength to withstand localized contact pressure at
all points of moving contact to prevent accelerated wear of the moving parts. The basic
principle in the selection of lubricants is to choose the least viscous that will retain a film
coverage and withstand the loading of the moving parts.
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Prior to filling the crankcase and gear reduction unit with lubricant (at the time of initial start-
up or anytime that the unit ahs been drained) remove the side covers, rear frame cover and
the side plate from the sludge trap to be certain that the interior of the pump is clean, free
of foreign material and condensation.
If the unit has been in operation, clean the oil pump suction strainer, clean the magnetic
filter, replace the oil filter cartridge, and clean the air breathers.
If the lubricant was contaminated with any type of foreign material, i.e., sand, dirt, metal
cuttings or chips, paint, light hydrocarbons, pumped product, etc., the system must be
purged on this material. Install a new filter cartridge and fill crankcase and gear unit with a
non-toxic, non-explosive solvent (refer to the lubrication specification plate on the unit or
the OWNERS MANUAL for the volume required to fill the unit) and circulate this fluid
without rotating the shaft assemblies or moving the reciprocating parts. To circulate this
fluid make by-pass connections around the oil pump and introduce an independently driven
pump into this system and use electric or pneumatic drill motor to activate the independent
oil pump. If the unit is equipped with an electric motor driven oil pump, use this to circulate
the solvent. Circulation should be maintained for a minimum of five minutes.
After circulating the solvent, remove the side covers, rear frame cover, drain the solvent,
inspect and clean the interior of the pump, change the filter cartridge, drain and clean the
sludge trap, and clean the oil pump suction strainer.
Close the drains and refill the unit with 20-W or 30-W mineral oil or non-detergent motor oil.
Circulate this oil the same as the solvent was circulated. After a minimum of five minutes,
continue to circulate this oil and slowly, without any loading rotate the crankshaft
approximately ten revolutions. Drain this oil from the pump and follow the same
procedures as that outlined for the removal of the solvent. Remove the independent oil
pump (if this was used to circulate the solvent and light weight oil), and reconnect the oil
pump suction and discharge lines.
When filling the unit with lubricant, close the drains; remove the side covers, top cover, rear
frame cover, etc., introduce copious quantities of the lubricant into the bearing reservoirs,
crosshead guides, crankpin bearing troughs, lubricate the crosshead extension rods, etc.
Also, remove the air breather from the gear reduction unit and deliver approximately 15
gallons (56.7 litres) of the lubricant through this opening and into the gear case. When
initially filled, the lubricant level should be above the “high” mark on the oil level dipstick,
but after a few minutes of unloaded operations, with the filling of the sludge trap and other
reservoirs, the oil level should be between the “high” and “low” marks on the dip stick.
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SERVICE CAPACITY TYPE LUBRICANT AGMA ISO VISCOSITY

PERIOD U.S. GAL. TEMPERATURE LUBRICANT GRADE
(OPERATING NUMBER
CONDITIONS)
Extreme Pressure 90º F. to 180º F 7 EP 460 EP

1 Month Heavy Duty
42
(Break-in Period) Industrial
Gear Lubricant 70º F to 170º F 5 EP 220 EP
Extreme Pressure 90º F. to 180º F 7 EP 460 EP

Heavy Duty
Every 6 Months 42
Industrial
Gear Lubricant 70º F to 170º F 5 EP 220 EP
LUBRICANT SELECTION
Proper lubrication is essential to trouble-free performance of all machinery. A film of

lubricant must be provided with sufficient strength to withstand localized contact pressures
at all points of moving contact to prevent accelerated wear of the moving parts. The basic
principle in the selection of lubricants is to choose the least viscous that will retain a film
coverage and withstand the loading of the moving parts.
EXTREME PRESSURE, HEAVY DUTY, INDUSTRIAL GEAR LUBRICANT
To provide for proper lubrication an EXTREME PRESSURE, HEAVY DUTY, INDUSTRIAL

GEAR LUBRICANT is introduced into the system and distributed to the moving parts. The
loading and operating conditions of these units dictates that this lubricant must qualify
under AGMA specification 250.04. (Sept. 1981) and have a Timken Load Arm Test of not
less than 60# O.K. The pour point of the selected lubricant should be 15 deg. F. below the
starting ambient temperature. Multi—Grade lubricants are NOT recommended.
13.1 General
Use only the quantity and grades of lubricant listed above.
Maintain the lubricant free of all contamination (fluids and solids).
Change lubricant at the end of the service periods listed above.
If contaminated, change lubricant immediately.
Maintain the temperature of the lubricant within the ranges listed above.
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Maintain continuous lubricant flow under all operating conditions.
Provide “no flow” alarm system.*
Provide alarm system for high lubricant temperature (set at 180 deg. To 190 deg. F.)*
Change the filter cartridge when the lubricant is changed.
Change the filter cartridge when the pressure across filter increases 15 psi.
Clean the magnetic filter every 8-hours during first week of operations.
Clean the magnetic filter once each month (after first week of operations).
Clean lubricant strainers once each month (minimum).
Drain sludge sump when draining crankcase lubricant.
Consult the manufacturer if additional information is required regarding the lubrication of this
equipment.
*To protect this valuable equipment it is recommended that shutdown switches be provided to function when
destructive conditions exist, e.g., the absence of sufficient lubricant, excessive lubricant temperatures, etc.
Refer to PLACING IN OPERATION in this publication for other instructions relative to lubrication.
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14 LUBRICATION SYSTEM
The lubrication system (excluding the liner flushing system) consists of an oil pump,
cartridge type oil filter, magnetic oil filter plus the necessary hose, fittings, gauges,
strainers, etc., to interconnect these components. This provides for the circulation of the
lubricant, its filtration and heating or cooling.
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An electric motor driven lubricating oil pump is provided to insure the flow of the lubricating
oil at slow pump speeds and that circulation of the oil can be achieved prior to loading the
pump.
CAUTION: Do not operate the pump in reverse rotation without consulting the pump
manufacturer because the internal lubrication system will not function properly.
The flow of lubricant discharged from the oil pump is directed through the magnetic filter,
the cartridge type filter and back into the power frame where it is distributed by the internal
lubrication system.
The external lubrication piping can be arranged with valves to permit the oil to by-pass the
filters while these are being serviced. Do not by-pass the filters unless absolutely
necessary, and then only for a short interval.
MAGNETIC OIL FILTER
The magnetic oil filter functions to collect and retain particles of ferrous metals that circulate
in the lubricating oil. It has no moving parts and requires little attention except for cleaning.
The magnetic oil filter must be cleaned every 8 hours during the first week of operations
and at least once each month after the first week of operation.
OIL FILTER (Cartridge Type)
The cartridge type oil filter is designed to remove solids from the lubricating oil. Water,
acid, light hydrocarbons, etc., may pass through the filter and destroy the lubricity of the oil,
if these are present or if the oil contains more than a very slight amount of solids, do not
rely on the oil filters – remove the pump fro service immediately, and be guided by the
instructions outlined under LUBRICATION in this publication.
Pressure gauges should be provided to determine the pressure at the inlet to the filter and
at the outlet from the filter – when the differential pressure between these two gauges is as
much as 15 p.s.i.g (103.42 kPa) [at opening temperature] immediately remove the pump
from service or by-pass the oil around the filters, remove the filter cartridge, clean the
cartridge case and install a new cartridge. Also, install a new filter cartridge every time the
oil is changed. Examine the used filter cartridge to determine the type of contamination it
has removed form the oil, locate the source of the contamination it has removed from the
oil, locate the source of the contamination and take remedial action.
The electric lubrication system may be energized to establish flow several minutes before
the pump is placed in operation and to flush the system when contamination of the lubricant
dictates this requirement.
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15 LINER FLUSHING SYSTEM
This is a closed circulation system which unlike flow-thru systems aid in the control of
environmental contamination.
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The liner flushing system plays a very essential part in the successful operation of this
single acting piston pump. The flushing fluid lubricates and cools the piston during the
suction stroke. It also aids in the removal of any solids that may have by-passed the
piston, thus reducing wear on both the piston and liner.
The flushing pump is independently driven by a three horsepower electric motor. Total flow
is approximately 60 g.p.m. (U.S.) (3.785 l/s).
A flushing media of 90% water and 10% water soluble oil should be introduced into the
pump cradle section where it will gravitate to the flushing sump to be screened and
circulated to the liner/piston assembly. If water is used, be certain to protect the system
during cold weather.
At initial start-up, after the reservoir is filled, it may be necessary to remove the plug from
the top of the pump volute to permit air to estace from the system and prime the pump.
Make sure that all flushing lines are clear and that unrestricted constant flow is maintained.
Check the flushing shield periodically to make sure that it is properly adjusted to direct the
spray inside the liner and on the piston for the full length of the pump stroke.
Some pump/motor assemblies require lubrication – check the instruction plate on the
assembly to determine if lubrication is necessary.
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16 STRAINER MAINTENANCE
The objective of the discharge strainer is to prevent large particles and objects from being
circulated through the mud system and down-hold. The strainer has an access cover for
clean-out and contains three O-ring seals to prevent fluid leakage through the cover thread
and inside by the strainer screw.
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16.1 Maintenance
Removal of collected debris periodically depending on specific drilling fluid condition.
Inspection of strainer tube for fluid errosive and corrosive wear.
Inspection of O-ring seals and strainer body for initiation of fluid cuts or other damage.
16.2 Removal
Remove strainer cover
Remove the discharge strainer tube.
Clean the strainer and the strainer block. Pay particular attention to O-ring sealing surfaces.
Inspect the cover and strainer tube, O-ring grooves for damage or wear.
Inspect three (3) O-rings for deterioration or physical damage – replace if questionable.
Inspect strainer cover and body threads at this time for evidence of physical damage or fatigue
initiation. Replace components as required.
16.3 Installation
Place O-rings onto strainer cover and discharge strainer tube with light amount of grease.
Lubricate O-ring sealing surfaces inside body and light coating of grease.
Lubricate strainer cover threads with anti-seize compound.
Assemble strainer tube into body carefully not to damage O-rings.
Assemble strainer cover onto body being careful not to damage O-rings.
Spin cover on until hand tight. Mark the position of cover with respect to body. (Use pencil, chalk,
etc.).
Torque strainer cover to 1000 ft.-lbs.
Mark on cover should advance approximately 1/16 inch (1.587mm).
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A heavy bar thru holes in the cover will facilitate torquing. Do NOT pound directly on cover.
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17 TECHNICAL INFORMATION
A600-PT MUD PUMP
The following details are presented to permit identification of the valve service pistons and
piston rods under industry standards, as a guide to the proper setting or clearance of
rotating and reciprocating parts and includes data pertinent to the unit or its function.
ROTATING AND RECIPRROCATING PARTS
Pinion Shaft Bearings:

Type………………………………………………………….Straight and Spherical
Clearance……………………………………………………………Non-adjustable
Lateral Clearance of Shaft……………………………… .002” to .010” End Play
Crankshaft Bearings:
Type………………………………………………………………………….Tapered
Clearance…………………………………………………………………Adjustable
Lateral Clearance of Shaft…………………………..…. .000” to .002” End Play
Intermediate Bearings:
Type…………………………………………………………..............Straight Roller
Later Clearance of Shaft…………………………..…… .000” to .002” End Play
Countershaft Bearings:
Type………………………………………………………….Straight and Spherical
Lateral Clearance of Shaft……………………………… .002” to .010” End Play
Connecting Rod (or Crank Pin) Bearing:

Type…………………………………………………………………..Precision Type
Crosshead Pin Bearing (or Bushing):

Type…………………………………………………………..............Straight Roller
Clearance – Crosshead Pin in Crosshead……………..... .000” to minus .003”
Clearance – Bearing or Bushing to Crosshead Pin……….…….Non-adjustable
Crosshead:
Clearance – (Diametrical) Crosshead to Crosshead Guide……. .010” to .015”
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VALVE SERVICE
Size……………………………………………………………………………….…API SA-4
Accessibility………………………………………………………………………..Individual
Covers……………………………………………………………………………Screw Type
PISTONS
Designation…………………………………………………………………………API SA-4
Function………………………………………………………………………..Single Acting
Material*……………………………………………………………………….Nitrile Rubber
PISTON RODS
Designation…………………………………………………………………………API SA-4
Function………………………………………………………………………..Single Acting
Material…………………………………………………………...Steel-Phosphate Coated
CYLINDER LINERS
Material……………………………………………………………………..Super DI-HARD
MISCELLANEOUS
Tools: (Optional Except as Shown)
Valve Seat Puller…………………………………………………………Hydraulic*
Tool for Piston Installation & Removal……………………Furnished With Pump
Tool for Piston Rod Nuts………………………………Spline Wrench or Socket*
Mechanics Tools (Sockets, Box End Wrenches, etc.)…Wrench for 2-3/8” Nut*
*May be purchased separately from pump manufacturer.
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18 APPENDIX
18.1 Maintenance
18.1.1 General
The requirement for a maintenance program cannot be over emphasized. This equipment
represents a considerable investment and its function is necessary to your operations.
Neglect is costly and will result in premature failures, early retirement of worn equipment
and junking of unusable machinery.
The installation of a maintenance program with positive execution will reward your
operations economically by:
Reduce down-time.
Reduce quantity of required repair and replacement parts.
Provide for longer periods of service-free operations.
Extend the life of your equipment.
18.1.2 Provisions for Maintenance
It is strongly recommended that all pumping operations be supported with stand-by

capacity and by a spare parts inventory. The percentage of stand-by capacity needed to
sustain operations is determined by the operator and the quantity of spare parts in his
inventory is usually dictated by use patterns. Spare parts should be maintained in
inventory to be immediately available at the point of operations.
18.1.3 Suggested Minimum Program
The following represents a suggested MINIMUM requirement for maintenance. It is designed for
periodic inspection and adjustment, it does not preclude the necessity of immediate attention to
items or elements which become maladjusted or worn nor is it intended to remove the “common
sense” factor which is so necessary in the operation of any mechanical equipment.
As indicated above, this is only a guide, other maintenance may be desirable and required to
satisfy your safety program, to comply with established policies, etc.
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DAILY CHECKED RECORDED

1 Check oil level in crankcase or circulating tank
2 Check oil pressure
3 Check oil temperature
4 Check oil for contamination
5 Check for filter cartridge change
6 Lubricate flushing pump
7 Check piston for leakage
8 Drain plunger leakage sump tank
9 Check pump inlet pressure
10 Check discharge pressure
11 Check for oil leaks
12 Check for fluid leaks
13 Check suction stabilizer for proper pressure or fluid level
14 Check discharge pulsation dampener for proper pressure
15 Check flushing system
16 Check for diaphragm leakage
17 Check oil seals for leakage
18 Check heat exchanger for leakage
19 Check pump for cleanliness
20 Check work area for cleanliness
WEEKLY CHECKED RECORDED
1 Check all fluid end and power end bolting
2 Check foundation and/or hold-down bolts
3 Check inlet flange bolting
4 Check discharge flange bolting
5 Check piston rod couplings
6 Check all safety controls for malfunction
MONTHLY CHECKED RECORDED
1 Check piston wear
2 Check extension rod or pony rod for wear
3 Clean oil strainer
4 Clean flushing pump strainer
5 Clean sludge trap
6 Clean crankcase breather
7 Check valves, seats and springs
8 Check availability and condition of tools
9 Change flushing media
SIX MONTHS CHECKED RECORDED
1 Check crosshead clearance
2 Check crosshead pin clearance
3 Check main bearing clearance
4 Check pinion shaft or sprocket shaft bearing clearance
5 Check crankpin bearing clearance
6 Check gears and/or chain and sprockets for wear
7 Check pump sheave, sprocket for coupling
8 Change oil (also change filter cartridge)
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18.2 Trouble Symptoms
It is not possible to diagnose, without a very careful examination, the cause of all difficulties
which may arise in any pumping operation. The more common symptoms are listed below.
If the remedy outlined here does not alleviate the difficulty, please refer the matter to the
manufacturer’s technical services department.
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18.3 Torquing Values
The proper torquing of all bolts, studs and capscrews is IMPORTAN. Improper torquing will
cause breakage by fatigue or yield and serious damage or hazards can ensue.
Thoroughly clean all threads, internal and external, at the time of installation.
Lubricate all threads, internal and external, with a good quality anti-seize compound.
Be certain tightening progresses uniformly to prevent misalignment or damage to the components.
The following values are to be observed in the final tightening of the fasteners.
ALLOY STEEL STUDS CAPSCREWS AND BOLTS

(SAE grade 7 or equal) (SAE grade 5 or equal)
Diameter Required Torque Threads Diameter Required Torque
IN (mm) LBS-FT (kg-m) Per Inch IN (mm) LBS-T (kg-m)
1/4 ( 6.35) 6.22 ( .86) 20 1/4 ( 6.35) 5.06 ( .70)
5/16 ( 7.92) 12.9 ( 1.78) 18 5/16 ( 7.92) 10.4 ( 1.44)
3/8 ( 9.53) 23.9 ( 3.31) 16 3/8 ( 9.53) 16.5 ( 2.28)
7/16 (11.10) 36.6 ( 5.06) 14 7/16 (11.10) 29.6 ( 4.09)
1/2 (12.70) 55.8 ( 7.72) 13 1/2 (12.70) 45.2 ( 6.25)
5/8 (15.88) 111. ( 15.4 ) 11 5/8 (15.88) 90. ( 12.4 )
3/4 (19.05) 196. ( 27.1 ) 10 3/4 (19.05) 159. ( 22.0 )
7/8 (22.23) 318. ( 44.0 ) 9 7/8 (22.23) 236. ( 32.6 )
1 (25.40) 477. ( 66.0 ) 8 1 (25.40) 354. ( 49. )
1-1/8 (28.58) 675. ( 93.4 ) 7 1-1/8 (28.58) 475. ( 65.7)
1-1/4 (31.75) 955. (132. ) 7 1-1/4 (31.75) 675. ( 93.4)
1-3/8 (34.93) 1245. (172. ) 6 1-3/8 (34.93) 877. (121. )
1-1/2 (38.10) 1762. (243.4 ) 6
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18.4 Torquing Sequence
A pattern or sequence for the torquing of fasteners is necessary for the proper installation
of many machinery components.
Bearing housings, flanges, covers, etc., retained with multiple fasteners, should have equal
“stand-off” and clamping force in all areas.
The above sketch reflects the “cross over” pattern for the torquing of the fasteners. It is
suggested that all fasteners be installed “hand tight” and that the torquing be applied in two
steps. First, apply half torque to fastener number 1, then number 2, then number 3, etc.
When half torque has been applied to all the fasteners, apply full torque to fastener number
1, then number 2, etc., until all the fasteners have been fully torqued.
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18.5 Shear Blocks
18.5.1 General
Machinery items are generally mounted on machine pads, “H” beams or bed-plates and
retained with capscrews or hold-down bolts. The flexing of loaded machinery will cause
these capscrews or hold-down bolts to become loose and ineffective for the retention of
alignment of machine with its associated equipment. When the equipment is being made
ready for operations it should be carefully aligned, secured with the capscrews or hold-
down bolts, then its position reinforced with dowel pins or shear blocks (this is applicable to
items which need to be moved, i.e., pumps, rotary tables, etc., however, engines or other
prime movers which must be moved for belt or chain drive adjustments should be equipped
with slide rails and in these installations the slide rails should be “doweled” or “blocked”).
Also, the shear blocks serve a dual purpose, they are guides, for the reinstallation of a
machinery item once it has been removed from its base for servicing or any other reason.
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18.5.2 Installation
As indicated above, be certain that the equipment is in alignment and that the capscrews or hold-
down bolts are properly tightened.
Hold the shear block firmly in place and tack-weld it at point “A”.
Continue to hold the shear block in place and weld side “B” – start at the outside corner and weld
continuously toward the retained, object.
Weld side “C” – again, start at the outside corner and weld continuously toward the retained
object.
Shear blocks should be installed opposite to each other – this placement with this outlined welding
procedure will then place the retained object in compression.
Recheck the alignment of the equipment. If it has been distorted, remove the shear blocks,
realign the equipment and proceed with these same instructions to install new shear blocks.
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18.6 Storage of Pumps
All machinery units require protection from corrosion/erosion, natural attrition which causes
deterioration of the surface as well as the working parts. Generally, units in operation are
frequently inspected, cleaned, painted and lubricated while idle units are often more or less
neglected. Any degree of neglect is costly, especially if continued over a sufficient period
of time to make restoration of the equipment impossible. It is recommended that preventive
measures of protection be established and the following will guide you in the minimum
requirement.
18.6.1 General
Preferably, units should be stored in clean, climatically controlled building. Which would
require the minimum inspection, but, since storage in other environments is sometimes
necessary, more frequent inspections and additional protection is necessary. The schedule
for inspection and protection can be determined only at the point of storage. A protection
and storage log is recommended. Tropical areas require the maximum protection, arid
regions require the least amount of protection. The frequency of inspection is determined
after noting the rate of deterioration. Take positive action immediately when
corrosion/erosion appears, do not wait until large areas are covered, because usually the
larger the area, the deeper the penetration.
18.6.2 Initial Storage Recommended Protection
(1) Drain all oil and thoroughly clean inside of Power Frame.
(2) Coat pinion shaft oil seals with grease.
(3) Remove breathers for later installation on pump. Seal all breather holes with
greased solid plugs. Remove extension rods and diaphragm sealing housing, protect
suitably and store separately for later installation on pump. Seal diaphragms with wooden
covers. Mating faces of covers and diaphragm to be thoroughly coated with Rust Veto 342
or equivalent.
(4) Spray 20 gallons of Shell VSI 100 vapor phase inhibitor or equivalent into power end
of pump.
(5) Remove valves and valve springs. Clean and wrap it in corrosion inhibiting paper.
Remove liners and pistons. Clean and wrap in corrosion inhibiting paper. Clean and dry
fluid end bores and thoroughly coat all internal surfaces with Tectyl 506 or equivalent.
(6) Thoroughly coat threads and end of valve cover and screw into fluid end.
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(7) Protect all external machine surfaces using Rust Veto 342 or equivalent including
pump pads.
(8) Inspect complete pump and record all detains on to Protection and Storage Log.
18.6.3 Six Weekly Servicing
Partially remove protective covering.
Rotate jackshaft 10 revolutions.
Inspect for soundness of external protection i.e. rust preventative and paint. Renew as
necessary.
Re-cover with protective covering.
Enter and record all details onto Protection and Storage Log.
18.6.4 Six Monthly Servicing
2. Remove completely protective covering.
3. Rotate jackshaft 10 revolutions.
4. Renew internal rust inhibitors to specifications and quantities previously stated under
initial storage.
5. Before replacing side covers and top cover, inspect for any internal corrosion.
6. Inspect for soundness of external protection i.e. rust preventative and paint. Renew as
necessary.
7. Replace protective covering.
8. Enter and record all details onto Protection and Storage Log.
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18.6.5 Pre-Installation Check After Storage
1. Repeat 6-monthly servicing procedure as above.
2. Ensure all necessary parts are complete and in a satisfactory condition for installation
on pump.
3. Enter all records and close Protection and Storage Log.
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Installation, Care and

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Client Document Number A-600-PT-MAN-001 02

02 12.02.2005 Updated to new template PG

Revision Change Description

8.1 General ................................................................................................................. 26

16.3 Installation ............................................................................................................ 67

The materials used in construction of National Oilwell mud

Variations in requirements may demand relocation or the omission of certain components

3 FLUID END ASSEMBLY

1. Fluid Chamber (7) Piston Rod Extension

1. Maintain proper tightness of all fluid end bolting.*

*Torquing values will be found in the APPENDIX of this publication.

*Torquing values will be found in the APPENDIX of this publication.

(6) Valve Nut

4. Replace damaged or fluid cut assemblies immediately. It is recommended that a complete

5. Keep the suction and discharge manifold bolting tight.*

• Lift out the valve assembly.

5 PISTONS AND LINERS

1. Piston Rod Nut

- Replace worn or deteriorated piston assemblies immediately.

- Maintain liners in good condition or replace to prevent piston failures.

- Replace the piston rod nut if damaged or if seal is deteriorated.

• Disconnect the pump from its power source.

• Remove the extension rod clamp.

14.1. “O” Ring

17. Install the liner flushing shield.

18. Install the extension rod clamp.*

*Torquing values will be found in the APPENDIX of this publication.

To prevent the necessity of removing the subassemblies because of improper care, it is

• Install the hold-down capscrews, but do not tighten it.

• Tighten the hold-down bolts.*

• Replace guards, safety railings, etc.

*Torquing values will be found in the APPENDIX of this publication.

• Keep the vent holes and drain holes free of obstructions.

*Torquing values will be found in the APPENDIX of this publication.

• Observe the foregoing instructions to install the other diaphragm assemblies.

*Torquing values will be found in the APPENDIX of this publication.

Remove the frame end plate with its gasket.

*Torquing values will be found in the APPENDIX of this publication.

*Torquing values will be found in the APPENDIX of this publication.

EXCEPTIONS TO PARAGRAPHS 5 and 6 ABOVE

When this situation is encountered it is suggested that the instructions in paragraph 5

*Torquing values will be found in the APPENDIX of this publication.

*Torquing values will be found in the APPENDIX of this publication.

Install the crankshaft key.

Install the countershaft assembly. Refer to COUNTERSHAFT ASSEMBLY in this

*Torquing values will be found in the APPENDIX of this publication.

Cross Pin: Bushing

Crosshead: Crosshead Guide

Crosshead Pin: Crosshead

*Torquing values will be found in the APPENDIX of this publication.

Install the upper and lower shoes on the crossheads.

*Torquing values will be found in the APPENDIX of this publication.

8. Normal running diametrical clearance should be maintained as follows:

8.1 Crosshead Pin Bushing:

8.2 Crankpin Bearing:

Press the crosshead pin bushings from the connecting rods.

Install the cotter pins in the connecting rod cap bolts.

*Torquing values will be found in the APPENDIX of this publication.

Keep the air breather clean.

Remove the air breather.

*Torquing values will be found in the APPENDIX of this publication.