PROPERTY OF DRAWN BY: REVISION

A. Simpson 01
Document No.
DATE: SHEET
X-201531-39-03
04/02/12 1 OF 3

DESIGN REQUIREMENTS

FOR

TRIPLEX PUMP, E-DRIVEN

3000 PSI (206 BAR), 75 HORSEPOWER,
460 VAC, 3-PHASE, 60 HZ

Checked By: Lingo Chang Date: 04/02/2012

Approved By: Ray Arbor Date: 04/02/2012

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned to
CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY: REVISION
A. Simpson 01
Document No.
DATE: SHEET
X-201531-39-03
04/02/12 2 OF 3

Equipment Name: Pump, Triplex

MFG Name: NOV/Bear Pump and Equipment, Inc.

MFG Number: Model BD-85M (A221630754A03 w/o motor)

Technical Data

Pump Model BD-85M

Working Pressure 3000 PSI (206 BAR)
Flow Rate 40.0 Gallons per minute (Minimum)
Suction Connection 2-1/2” NPT Female
Discharge Connection 1-1/2” NPT Female
Sealing Material Suitable -for hydraulic fluid service
Material Steel
Belt guard must be non sparking material
Fluid Oil-Based Hydraulic Fluid (ISO 32)
Operating Temperature -4°F to +113°F (-20°C to + 45°C)
Max Fluid Temperature 110°F (43°C)
Drive V-Belt Drive Belt Assembly to be Non Sparking, Anti Static
Belt guard must be provided with an inspection port with bolt on
cover to allow for belt inspection and to check belt tension.
Mounting Pump, motor drive to be mounted on a self contained heavy duty
frame
Painting Manufacture’s standard
Orientation Vertical base mount, Motor Above pump. Looking at the belt guard
the fluid end is to be on the left side.

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned to
CAMERON upon request and in all events upon completion of the use for which it is intended.
PROPERTY OF DRAWN BY: REVISION
A. Simpson 01
Document No.
DATE: SHEET
X-201531-39-03
04/02/12 3 OF 3

Documentation Dimensional Installation drawing (ACAD format) for approval.

BOM
Assembly Drawing (ACAD format) with item # cross reference to
BOM.
Manufacturer’s recommended spare parts kit(s), i.e. V-belt part
number.
Operation and Maintenance Document

Certification ATEX certification required

This document contains confidential and trade secret information which is the sole property of CAMERON. Receipt or possession does not convey any right to loan, sell or otherwise disclose said
information. Reproduction or use of said information for any purpose other than that for which it is intended may not be made without written permission from CAMERON. This document is to be returned to
CAMERON upon request and in all events upon completion of the use for which it is intended.
BEAR PUMP & EQUIPMENT, INC.

INSTALLATION, OPERATION
and
MAINTENANCE MANUAL

MODEL BD-60 & BD-85

Triplex Reciprocating Pump

REV. 082304
 MANUAL PURPOSE

THE PURPOSE OF THIS INSTRUCTION MANUAL IS TO ASSIST THE PERSONS

RESPONSIBLE FOR THE INSTALLATION OF THE PUMPING UNIT. IT IS NOT INTENDED
TO COVER ALL THE DETAILS OF VARIATIONS WHICH MAY ARISE IN CONNECTION
WITH THE INSTALLATION OF THE PUMP, HOWEVER, IF ADDITIONAL INFORMATION IS
DESIRED TO COVER A PARTICULAR SITUATION WHICH IS NOT INCLUDED, CONTACT
THE MANUFACTURER OR AN AUTHORIZED REPRESENTATIVE.

WARNING

This manual provides the equations FOR REFERENCE ONLY, to assist in providing
information with regard to reciprocating pumps. In no way is any responsibility assumed for
the abridged form and equations provided in the manual. See the Hydraulic Institute
Standards for a complete definition and standards.

IDENTIFICATION

THIS INFORMATION HAS BEEN PREPARED FOR THE FOLLOWING UNIT(S):

CUSTOMER:
CUSTOMER ORDER NO:
PUMP SIZE & TYPE:
PUMP SERIAL NO:
PUMP ITEM NO:
SERVICE:
SHOP ORDER NO:
 TABLE OF CONTENTS

1.0 Design Considerations for Reciprocating Pump Applications

1.1 System Design Considerations
1.2 Reciprocating Pump Piping Guidelines
1.2.1 Suction Piping
1.2.2 Discharge Piping
1.2.3 Multiple Units
1.2.4 Acceleration Head Phenomenon
1.2.5 Foundation
1.2.6 Piping
1.2.7 Alignment Between Pump & Driver
1.2.8 V-Belt Drive
1.2.9 Suction Head Pressure
1.2.10 Relief Valve & Bypass
2.0 Installation, Operation, & Maintenance for Reciprocating Pumps
2.1 Installation of the Pump
2.1.1 Rotation
2.1.2 Pump & Driver Foundations
2.1.3 Alignment Between Pump & Driver
2.1.4 V-Belt Drive
2.1.5 Belt Removal
2.1.6 Belt Replacement
2.1.7 Belt Adjustment
2.2 Operation of the Pump
2.2.1 Lubrication
2.2.2 Starting Pumps Under Load
2.2.3 Loading & Unloading
2.2.4 Precautions for Starting Under Load
3.0 Disassembly & Assembly Instructions
3.1 Power Frame Disassembly
3.2 Power Frame Reassembly
3.3 Fluid Cylinder Removal & Disassembly
3.3.1 Suction Valve & Seat Removal
3.3.2 Discharge Valve & Seat Removal
3.3.3 Stuffing Box Disassembly
3.4 Fluid Cylinder Assembly & Replacement
3.4.1 Assembly of Stuffing Box
3.4.2 Installation of Suction & Discharge Valve Seats
3.4.3 Reassembly of Discharge Manifold
3.4.4 Reassembly of Suction Manifold
3.4.5 Mounting Fluid Cylinder Assembly
3.5 Instructions for Packing Installation & Adjustment
3.5.1 Instruction for Square Ring Type Packing
3.5.2 Instructions for Molded “V” Ring Type Packing
3.5.3 Instructions for Non-Adjustable Packing
4.0 Engineering Data
Chart 4.0 – Engineering Data Sheet
Chart 4.1 – Reciprocating Pump Comparative Flow Curves
Chart 4.2 – Reciprocating Pump Speed & Torque Curves
Chart 4.3 – Standard Materials & Construction
Chart 4.4 – Pump Temperatures & Frame Loads
 SECTION 1.0

SY STEM DESI GN CO NS IDERAT IO NS

FOR

RECIPROCAT ING PUMP

APPLICATIONS
1.0 DESIGN CONSIDERATIONS FOR
RECIPROCATING PUMP APPLICATIONS

1.1 SYSTEM DESIGN CONSIDERATIONS

The following information is presented as a check list to minimize installation and service problems when installing
a pump and servicing the pump after installation.

DESIGN CHECKLIST
1.1.1 INSURE THERE IS ENOUGH SYSTEM HEAD 1.1.7 IS THERE A PULSATION BOTTLE (OR AT
PRESSURE TO PROVIDE MINIMUM NPSHa REQUIRED LEAST PROVISION FOR ONE) NEAR PUMP SUCTION?
BY THE PUMP AND OVERCOME THE ACCELERATION
HEAD PLUS FRICTION LOSS. 1.1.8 IS THERE A PULSATION DAMPENER (OR AT
LEAST PROVISION FOR ONE) NEAR PUMP DIS-
(NPSH=SUCTION HEAD – VAPOR PRESSURE) CHARGE?

1.1.2 HAS A WEIR/BAFFLE PLATE BEEN UTILIZED 1.1.9 IS THE RELIEF VALVE SIZED TO PASS TOTAL
TO HELP RELEASE TRAPPED GASES? PUMP FLOW AT RELIEF VALVE PRESSURE SETTING?

1.1.3 HAS A VORTEX BREAKER MECHANISM BEEN 1.1.10 IS THERE A CAPACITY CONTROL VALVE IN A
UTILIZED IN THE SYSTEM? BYPASS LOOP?

1.1.4 IS SUCTION VELOCITY WITHIN RECOM- 1.1.11 ARE THE INLETS BELOW MINIMUM FLUID
MENDED LIMITS? IF MARGINAL, IS A LARGER SUC- LEVELS?
TION LINE WITHIN SYSTEM LIMIT? (SEE HYDRAULIC
INSTITUTE STANDARDS) 1.1.12 IS THERE A CHECK VALVE IN THE DIS-
CHARGE PIPING?
1.1.5 HAVE ALL UNNECESSARY PIPING BENDS
BEEN MINIMIZED? (USE LONG RADIUS BENDS 1.1.13 IS DISCHARGE VELOCITY LIMITED TO 3
WHERE POSSIBLE) TIMES SECTION? IS THE NUMBER OF TURNS LIM-
ITED, AND IS THE LINE FULLY SUPPORTED?
1.1.6 ARE SUCTION VALVES THE FULL OPEN
TYPE?

Reservoir
Vent
1.1.11
Elevation of
Reservoir 1.1.1
Tank Inlet 1.1.13
1.1.5

1.1.2 1.1.7 1.1.8

1.1.10
1.1.9
1.1.3
Discharge 1.1.12
1.1.4
1.1.13
1.1.5
1.1.6 Suction Pump Fluid End

ILLUSTRATION 1.0

1.2 RECIPROCATING PUMP
PIPING GUIDELINES
1.2.1 SUCTION PIPING
Be as short and direct as possible in piping layout.
Use one or two pipe sizes larger than pump suction
connections. Use the following for calculation of
effective pipe size. A triplex pump should have a
velocity less than 2 ft/sec for speeds up to 250 RPM,
1-1/2 ft/sec for speeds up to 330 RPM and 1 ft/sec
for speeds above 330 RPM. For a quintuplex, these
velocities may be increased 70% or as determined
by the system design.
All systems should contain a minimum number of
turns. Necessary turns should be accomplished with
long-radius elbows or laterals.
Piping should be designed to preclude the collection
of vapor in the piping. (No high points unless
vented. Use eccentric reducer at pump cylinder with
flat side up.)
WARNING
System piping should incorporate
designs so that NPSH required, including
acceleration and friction loss, do not
exceed the NPSH available from the
system.
The following equations are provided
FOR REFERENCE ONLY, to assist in
providing information with regard to the
pumps. No responsibility is assumed for
the abridged form of equations provided
in this manual. See the Hydraulic
Institute Standards for complete
information and definitions.
Hydraulic Institute Standards
H2+Hf+NPSHR<NPSHa
Also include a suitable pulsation damper installed
adjacent to pump cylinder if it is found that the
acceleration head is excessive. Design
considerations must be taken into account in the
application of dampeners to suction systems since
many dampeners are not suitable for low pressure
application.
1.2.2 DISCHARGE PIPING
Designs should incorporate short and as direct as
possible piping pressure lines. Discharge pipe
should be one or two pipe sizes larger than pump
discharge connection, providing a velocity not
exceeding three times the suction velocity. Utilize a
minimum number of turns, utilizing long radius
elbows and laterals where possible. Piping should
include a check valve, relief valve, and a suitable
pulsation dampener adjacent to the pump cylinder,
or provision to add a dampener at a later date.
1.2.3 MULTIPLE UNITS
Designs including two or more pumps connected to
a common suction and/or discharge line require the
capacities of all pumps which run simultaneously to
be added for determination of line velocities. Design
care must be exercised to prevent a mutually
reinforcing pressure wave from multiple units. Avoid
this possibility by utilizing independent lines as often
as feasible.
The above design guidelines are Hydraulic
Institute recommendations and criteria
established by experienced designers of
systems containing reciprocating pumps. The
pump manufacturer cannot assume
responsibility of system design into which the
pump is installed. That responsibility must lie
with the system designer. The above guidelines
are offered only as an aid to those involved in
the system design.
1.2.4 ACCELERATION HEAD
PHENOMENON
Piping design for a reciprocating pump requires
more consideration than piping for a centrifugal
pump. Based on the fluid in the suction line
pulsation (accelerating and decelerating), a certain
amount of energy is required to produce the required
acceleration. This energy is in addition to the friction
loss and is usually referred to as “Acceleration
Head”.
If sufficient energy is not available to accelerate the
liquid in the suction line, the liquid will flash, the
suction and discharge lines may shake, and the
pump will operate loudly and less efficiently. It can
fracture a fluid cylinder with the high pressure
surges that occur in the cylinder when the fluid
flashes.
To calculate the head required to accelerate the
fluid, the following equation is offered as an aid in
system design:
Ha = LVNC K
32.2
Ha = Head (in feet of liquid pumped) to produce the
required acceleration.
L = Actual length of suction pipe, feet – (not
equivalent length)
V = Mean velocity of flow in suction line – ft/sec
N = RPM of pump
C = 0.200 for Duplex Single-Acting
0.115 for Duplex Double-Acting
0.066 for Triplex
0.040 for Quintuplex
K = 2.5 for relatively compressed liquid
1.4 for liquid with almost no compressibility
(de-aerated water)
2.0 for most hydrocarbons
1.5 for amine, glycol, water
The above equation is based on non-elastic suction
line.
It should be noted that as the pump speed is
increased, both N and V increase. Therefore, Ha
varies as the square of pump speed. Ha also varies
directly with L.
To determine the amount of NPSH required in the
suction vessel, it is necessary to add these factors.
Total NPSHR = Static Head – Friction Loss -
Acceleration Head – Head Vapor
Pressure
It is possible to reduce the acceleration head by
installing a suitable pulsation dampener in the
suction line near the pump.
1.2.5 FOUNDATION
The pump should be set on a level rigid foundation.
Set the pump in a level manner so as not to place an
excessive strain on the pump mounting feet when
the foundation bolts are torqued. Shims may be
used under pump feet for leveling and stabilizing the
foundation mounting. Similar precautions should be
observed with respect to the driver in case where
the driver is mounted directly on the foundation.
1.2.6 PIPING
Pipelines should not be smaller than the connection
size on fluid end. For long pipeline runs, sizes for
both suction and discharge lines should be larger
than the fluid end connection sizes utilizing stepped
connections at the fluid end connection. The lines
should be as short and direct as possible minimizing
bends and fittings required. Use of large radius
sweeps rather than 90° elbows is recommended.
The suction line must be of sufficient size so that
acceleration and friction losses in the line plus the
losses through the pump itself (NPSH required by
pump) do not exceed the NPSHA (head or pressure
above vapor pressure of liquid) at the entrance to
the pipeline. The acceleration losses in the line are
usually much grater than the friction losses. It is
recommended that suction line velocities should not
exceed 1.5 ft/sec. Lower velocities are
recommended for long lines and speeds over 300
RPM for clear fluids. When the ambient temperature
through which the suction line passes is higher than
the liquid temperature, the effect of heat transfer to
the liquid raising the vapor pressure of the liquid
must also be considered.
NOTE
Pump system acceleration losses and
the pressure induced pulsation increase
with the length of the line, with the
velocity of liquid in the line and with the
RPM of the pump. Pulsation chambers
may sometimes be employed in the
suction line at the pump to reduce the
acceleration head and in the discharge
line at the pump to reduce the pulsation
in the discharge line. When used, these
must be suitable for the liquid and the
operating conditions. Inadequate NPSH
or pressure at pump inlet will cause
shock to the pump operation.
Pipe connections should be tightly made
to avoid liquid and air leaks. Valves used
in suction and discharge piping should
be full bore valves. Suction and
discharge piping should be arranged and
supported to avoid undue strains on
pump.
It is highly recommended that pipe
unions or flanges be installed close to
cylinder head. When making suction and
discharge pipe connections to pump,
quick-connection disconnects permit
convenient removal of the fluid cylinder
from the pump.
1.2.7 ALIGNMENT BETWEEN PUMP
AND DRIVER
When the pump is furnished with driver such as gear
head motor or motor and speed reducer, connected
couplings between the pump and driver shafts must
be carefully aligned. If a base is furnished, the
pump and driver are aligned prior to shipment.
 CAUTION
The alignment may be changed during
shipment and handling or in the
foundation mounting process.
Alignment should be checked prior to
operating the pump. Any misalignment
should be corrected using shims as
required for vertical alignment. Any
shimming that may be done should not
place a strain on the pump feet. If there
is any difficulty in avoiding strains, it
may be a base to foundation alignment
problem. In which case loosen
foundation bolts and shim under base as
required to eliminate strains in base
before tightening bolts which secure
pump and motor to base.
1.2.8 V-BELT DRIVE
It is necessary to monitor tension on a V-Belt drive
assembly for the first month. Adjustment of belt
tension should be made before slipping occurs and
damages belt. Do not over tighten belt, it will reduce
belt and bearing life. See belt manufacturer for
recommendations on tension settings.
When a top motor mount is used with the pump, V-
Belt tension should be adjusted equally on the three
motor mount plate screws. This will maintain proper
alignment. For more information see 2.1.4.
1.2.9 SUCTION HEAD PRESSURE
When volatile liquids are to be pumped, it is
necessary to provide sufficient suction head
pressure (HSP) to insure sufficient pressure above
the vapor pressure threshold (VP) of the liquid to
allow satisfactory filling and operation of the pump.
The amount of head or pressure above the vapor
pressure threshold of the liquid must be equal to the
acceleration (HA) and friction losses (F1) in the
pipeline plus the losses (NPSH required by pump)
through the pump.
Volatile Liquids Pumping Requirement
HSP > VP
Therefore, the following guideline is essential for
volatile liquid pumping.
HSP = HA + FL + NPSH
If the liquid to be pumped is not volatile and of
negligible viscosity, such as H2O (water), the
pressure at the pump inlet can be below
atmospheric pressure (vacuum at pump inlet), after
subtracting the line losses from the pressure at the
inlet point to the line. The optimum situation is to
have the pressure at the pump inlet equal to or
greater than atmospheric pressure.
NOTE
The maximum amount of vacuum at
pump inlet depends on operating
conditions of the total system.
Pumping viscous liquids requires
additional pressure compensation at
pump inlet. The amount of pressure
depends on the viscosity at pumping
temperature and other conditions such
as pump size and speed. Gases and
vapors are very detrimental to operation
of the pump. Precautions should be
taken to avoid this type of situation with
any liquid entering the pump.
If vapor pressure is present, it will cause
shock operation of the pump.
Insufficient head or pressure at pump
inlet will also cause shock operation.
1.2.10 RELIEF VALVE AND BYPASS
A relief valve must be installed in discharge line near
pump (See Illustration 1.0) and set to open slightly
above discharge pressure, to protect against
excessive discharge line pressure. The relief valve
should be sized to pass the total output of the pump
to relieve the discharge system of all pressure
exceeding the rated working pressure of the system.
Installing a manual bypass system will enable the
system and pump to be cleared of air or gases. The
bypass will allow gradual loading of the operating
pump by closing the bypass valve slowly.
If a bypass, incorporating a valve is provided
between suction and discharge lines near the pump
and a check valve provided in discharge line just
outside of bypass connection, it will provide a
method to relieve the pump of any load by opening
bypass valve. Additionally, it will provide a means to
apply load without undue shock while pump is in
operation, by gradually closing bypass valve.
NOTE
If a pump cylinder has suction and discharge
connections at both sides, bypass
connections can be made directly to
openings on one side of cylinder. The check
valve should be placed in the discharge line
on the opposite side of the cylinder. Bypass
lines returning to tank is the preferred
design; however, a bypass loop is
acceptable if it is a minimum of ten (10) feet
in length.
 SECTION 2.0

INSTALLAT ION, OPERAT ION,

AND MAINTENANCE

FOR

RECIPROCAT ING PUMPS

2.0 INSTALLATION AND OPERATION
FOR RECIPROCATING PUMPS
2.1. INSTALLATION OF THE PUMP
2.1.1 ROTATION
Direction of rotation must always be such that the
crankshaft extension rotates with the top of the shaft
moving towards the fluid end of the pump. The
direction of crankshaft rotation is also indicated by
rotation arrow.
WARNING
The pump will not lubricate if direction of
rotation is reversed. Incorrect hookup of
the pump will damage the pumping unit.
2.1.2 PUMP AND DRIVER
FOUNDATIONS
The pump should be set on a level rigid foundation.
Set the pump on a level plane; do not place an
excessive strain on the pump mounting feet when
the foundation bolts are torqued. Similarly, the
same precautions should be taken with respect to
the pump driver foundation mounting on installations
where the driver is mounted directly on the
foundation.
NOTE
Shims are used under pump feet and the
foundation mount points for leveling.
2.1.3 ALIGNMENT BETWEEN PUMP
AND DRIVER
When the pump is furnished with gear head motor or
motor and speed reducer, connected couplings
between the pump and driver shafts must be
carefully aligned. If a base is furnished, the pump
and driver are aligned prior to shipment and
installation can proceed. If a driver is to be coupled
to the pump on location, observe the following
caution:
CAUTION
The alignment may be changed during
shipment and handling or in the
foundation mounting process if mounted
individually. Alignment should be
verified prior to operating the pump.
Any misalignment should be corrected
using shims as required for vertical
alignment. Shimming should not place a
strain on the pump feet. If there is
difficulty in avoiding strains during
alignment, it probably is a base to
foundation alignment problem. In which
case, loosen foundation bolts and shim
under base as required to eliminate
strains before torquing bolts which
secure pump and motor to base.
2.1.4 V-BELT DRIVE
The following information is offered as a general
guideline. For specific information and technical
support about the drive belts being utilized, contact
the belt manufacturer or its representative direct.
Normally, it is necessary to adjust the tension on a
V-Belt drive assembly during installation. Do not
over tighten belt, it will reduce belt and bearing life.
See belt manufacturer for recommendations on
tension settings and Section 3.0 Maintenance of this
manual.
WARNING
If a top motor mount is used with the
pump, V-Belt tension should be adjusted
equally on the three motor mount plate
screws. This will maintain proper
alignment and prevent premature failure
of the drive belt and possible bearing
damage.
Do not install a used belt with a new belt
on multiple belt drive units. Keep used
belts for emergency replacement only.
NOTE
Use only a matched set of new belts.
Match numbers on belts are usually “46,”
“50,” “52,” “54,” etc. Each different
number represents a slight variation in
belt length. All belts used in the drive
should be the same match number.
2.1.5 BELT REMOVAL
Step 1: Loosen all motor mounting bolts, allowing
the motor to be shifted toward the pump.
Step 2: Shift the motor toward pump until belts are
easily removed over groove rim of the pulleys. Do
not pry or roll belts off as this may not allow enough
mounting space between the pulleys for installation
of the new belts.
2.1.6 BELT REPLACEMENT
Step 1: Slide the new belts over the motor and
pump pulleys. Care should be taken not to stretch
the new belts.
Step 2: Shift the motor away from pump until all belt
slack is on one side of drive pulleys (See Section
2.1.7 “Belt Adjustment” below) and torque all motor
mounting bolts to proper torque.
Step 3: Check motor and pump shafts for
alignment. Shafts must be parallel. If the pump and
motor are not in parallel alignment, loosen motor
mounting bolts, align, and retighten.
NOTE
Keep belts free from dirt and oil. Do
not use belt dressing.
2.1.7 BELT ADJUSTMENT
To calculate the correct belt tension, see Illustration
and measure the pulley span first, then multiply by
1/64. This is average deflection required on most
belts.
Belt Deflection =
1/64" x Span ( in inches )
FORCE
SPAN
( in inches )
ILLUSTRATION 2.0
At the center of the span apply a force at right
angles to the span in accordance to the Deflection
Calculation. Tighten belts until proper deflection is
obtained.
Measure each belt individually. Tension must be
same for all belts in the drive. V-Belts must be
operated under proper tension. Too little tension will
permit excessive slipping and result in shorter belt
life and loss of power. Too much tension will also
cause shorter than acceptable belt life. Proper
tension is just slightly above the point where
slippage is eliminated. This can best be determined
by measuring the speed ratio at no load and full
load. The change in speed ratio between no load
and full load should not exceed one percent (1%).
During the first thirty-six (36) hours of operation the
tension must be adjusted to compensate for initial
stretching and seating of the belts in the grooves.
2.2 OPERATION OF THE PUMP
2.2.1 LUBRICATION
The oil level should be maintained in a range from
the top of the oil gauge to ½” below the top of the
gauge as indicated with the pump stopped. When
adding oil, fill to the top of the gauge. Make first oil
change after 180 hours of operation. When
changing oil, remove crankcase cover and clean out
crankcase. Use SAE 10W40 non-detergent multi-
viscosity type oil for ambient temperature range from
0˚F to 115°F. Clean crankcase annually as a
minimum. See Chart 2.2 for recommended
crankcase capacities.
WARNING
When pump has been idle for an
extended time, sufficient to allow
lubricant to drain or escape from
bearings, start pump without load and
operate until lubrication is restored
before applying load.
NOTE
It is recommended that the oil
temperature be above 30˚F (0˚C) before
load is applied.
2.2.2 STARTING PUMPS UNDER
LOAD
Starting a power pump under load causes
tremendous strain on the pump and should be
avoided where possible. A piping system should be
provided which enables the pump to start against
negligible discharge pressure.
2.2.3 LOADING AND UNLOADING
Prior to start-up, the bypass valve, suction block
valve and discharge block valve, are all fully opened.
As the pump reaches approximately 70˚F on geared
units and 30˚F on direct units, the operator slowly
closes the bypass valve.
Recommended unloading of the pump is
accomplished by providing a bypass line from the
pump discharge line (connected between the pump
cylinder and discharge line check valve) to the 2.2.4 PRECAUTIONS FOR STARTING
suction line or preferably to the suction tank. UNDER LOAD
If necessary by process requirements, starting under
load can be tolerated if the following is practiced
WARNING according to Chart 2.1
If the bypass line is dumping fluid into
the suction line, closing the bypass valve
too slowly will cause the discharge
product to heat up and flash.
Safe Starting Under Load Check List:

1. Driver starting torque capabilities must be at

Disadvantages of Starting Under Load are: least 150% of full-load pump requirement.

1. Lubrication will not be flowing through the 2. Drive train sized for torque capability of motor.
lubrication system.
3. Pump is allowed to sit idle no more than 10-12
2. Bearings will not have a protective oil film. hours.

3. The load on bearings (and other power end 4. The fluid end is continually primed by reservoir
components) and on fluid end components will flow.
be higher than operating loads because of the
inertia of all rotating parts, and the inertia of all
fluid in the section and discharge lines. This CHART 2.1
fluid inertia can be quite large for long lines.

4. The drive components (gears, belts, and

couplings) will be loaded above their design
because of the inertias mentioned above.

5. The motor may be loaded beyond its capacity.

6. All pumping chambers of the fluid end do not

have an opportunity to become primed. This
can lead to reduced capacity and severe
vibration in the suction and discharge piping.

CHART 2.0
 LUBRICATION CHART

RECOMMENDED POWER FRAME CRANKCASE CAPACITIES

- DIRECT DRIVE -

PUMP MODEL APPROX. OIL REQUIRED OIL TYPE*

MX-3 Simplex 1.75 Quarts 1.7 Liters SAE 10W40

CX-5 Duplex 4 Quarts 3.8 Liters SAE 10W40
BX-10 Triplex 3.5 Quarts 3.4 Liters SAE 10W40
BD-28 Triplex 3.5 Quarts 3.4 Liters SAE 10W40
BD-30 Triplex 1.5 Gallons 5.7 Liters SAE 10W40
BD-60/85 Triplex 2.25 Gallons 8.5 Liters SAE 10W40
BQ-100 Quintuplex 3.25 Gallons 12.3 Liters SAE 10W40
BD-120 Triplex 5 Gallons 18.9 Liters SAE 10W40
BQ-200 Quintuplex 11 Gallons 41.6 Liters SAE 10W40

*For 0 to115°F. (-18° to 44°C) ambient temperature range

NOTES
1. Always use high grade non-detergent oil.

2. Run the pump at no load until oil temperature reaches approximately 30°F (0° C).

3. First oil change recommended after 180 hours of operation.

4. Subsequent changes recommended every 6 months or 2500 hours.

5. Crankcase should be inspected and cleaned every change.

6. Inspect or clean crankcase breather to insure free air flow.

NOTE: Severe duty environments may require more frequent changes.

CHART 2.2
2.2.5 OPERATING CHECK POINTS
The following points are suggested as a routing
operational check list, and as such, are not all
inclusive. Individual system designs will require
additional operational points to be checked for the
specific application in which the pump is being used.
Operational Check Points
BEFORE RUNNING PUMP
1. Fill power frame with proper oil (See
Lubrication Section 2.2.1). Fill oil to ½” from
the top of oil level gauge with pump not
running. Do not overfill.
2. Check plunger packing gland connections,
snug but do not over-tighten.
3. Check all cylinder bolting.
4. Check stuffing box for 360° contact with
cylinder.
5. Check all suction and discharge line valves
for open position.
6. Clean plunger drip pan area and verify the
drain hole is clear.
AFTER STARTING PUMP
1. Pump should run at no load until oil
temperature reaches 30°F. Check gasket
joints for leakage.
2. Check for excessive stuffing box leakage.
Some leakage is desirable to insure the
packing is lubricated.
3. Check oil seals for leakage.
4. Check power frame for overheating.
5. If a stuffing box lubricator is equipped on the
pump, adjust rate of injection. Normal rate
about 5-8 drops per minute per plunger.
TROUBLE SHOOTING CHECKLIST
1. No liquid discharge, erratic discharge or
cavitation.
2. Pump not primed and cleared of air.
3. Insufficient NPSH.
4. Suction line plugged.
5. Air pocket or air leak in suction.
6. Foreign matter causing valves to bypass.
CHART 2.3
 SECTION 3.0

DISASSEMBL Y AND ASSEMBLY

INSTRUCT IONS FOR

MODELS BD-60 & BD-85

3.0 DISASSEMBLY AND ASSEMBLY
INSTRUCTIONS
This section contains numerous references to parts
and procedures for the servicing of the pump. A
component’s description followed by a number
within
a set of parenthesis refers to a specific part
identified in Illustration 3.0 or 3.1 of this manual.
3.1 POWER FRAME DISASSEMBLY
Step 1: Remove thumb screws (36) and plunger
cover (37). Disconnect the plunger from the
crosshead assembly (10) and push the plunger as
far forward as possible.
Step 2: Remove drain plug (27) and empty the oil
from the crankcase. DISPOSE OF THE OIL
PROPERLY. Remove oil level indicator (28).
Step 3: Remove the hex head bolts (30) which
attach the crankcase cover (31) and the crankcase
cover gasket (32).
Step 4: Remove the crosshead stub deflectors (7).
Then remove the hex head bolts (8) & (18) which
attach the outboard frame cap (35), inboard frame
cap (21) (keeping the corresponding shim sets
together with the corresponding cap), and the
crosshead stub seal caps (5).
Step 5: Disconnect the connecting rod assembly
(13) from the crankshaft (25), and pull crosshead
(10) forward. Be sure to reattach the connecting rod
cap to the rod from which it was removed (these are
matched sets) after the crankshaft (25) is removed.
Step 6: Place a block of wood on the end of
crankshaft (25) and tap the crankshaft out the
opposite side of power frame (1). Then tap out the
remaining bearing cup (23). Keep the bearing cones
(24) and cups (23) matched together.
Step 7: Remove the crosshead assembly (10) and
the connecting rod assembly (13) out the rear of the
power frame (1) and tag each to identify the bore
from which it was removed.
Step 8: Clean out the crankcase removing any
sludge or residue collected in the bottom of the
crankcase.
Step 9: Remove the crosshead stub oil seals (6)
and replace each with a new one. These should be
pressed in with the seal faces opposed.
Step 10: Remove and discard the crosshead seal
cap gaskets (9).
Step 11: Remove and discard the crankshaft oil
seal (20). Press in new seal with the seal facing out.
Step 12: Remove the crosshead wrist pin set
screws (11) to allow removal of the wrist pin (12);
then remove and discard the connecting rod
bearings (15) and wrist pin bearing (14).
3.2 POWER FRAME REASSEMBLY
Step 1: Clean and inspect the crosshead
assembly (10). Examine the crosshead stub for any
nicks, dings, or longitudinal scoring. Check the
crosshead wrist pin bore for excessive wear as well
as fit tolerance with the new crosshead wrist pin
(12).
NOTE
A complete chart of fits and tolerances
is located in Chart 3.0. The fits and
tolerances are for new assemblies.
Certain considerations are necessary
for worn components. Torque
specifications for reassembly can be
found in Chart 3.1.
Step 2: Clean and inspect the connecting rod
assembly (13) and install new connecting rod
bearings (15) and wrist pin bearings (14). Hone the
wrist pin bearing to 1.5022 / 1.5020 after
installation.
Step 3: Assemble the crosshead assembly (10) to
the connecting rod assembly (13) by applying a thin
film of lubricant and inserting the crosshead wrist pin
(12) through the crosshead (10) and the small end of
the connecting rod (13). Secure the wrist pin (12)
with the wrist pin set screws (11).
NOTE
The crosshead wrist pin (12) is a slip fit
into the connecting rod (13) and is locked
into the crosshead assembly (10) with
two (2) set screws (11). Properly
installed, the connecting rod assembly
(13) slides to either inside position in the
crosshead assembly (10), allowing for
alignment of the connecting rod (13)
between the insides of the crosshead
(10) after attachment to the crankshaft
(25).
Step 4: Apply a thin film of lubricant to the
crosshead (10) and insert into the crosshead bore
from which it was removed and move to the full
forward position.
Step 5: Clean and inspect the crankshaft (25).
Examine the journals, where the connecting rods
(13) attach. These should be smooth and free of
dings, gouges, or circular wear lines.
Step 6: Clean and inspect the crankshaft bearing
cones (24) and cups (23) for damage or excessive
wear. Replace, if necessary, using a bearing puller
to remove the worn bearing cones (24) and a press
to install the new replacements.
NOTE
Always replace the bearing cup (23)
when replacing the bearing cone (24).
Step 7: Tap one crankshaft bearing cup (23) into
one side of the power frame (1) until flush with the
outside of the power frame.
Step 8: Remove connecting rod (13) caps and set
on top of crankcase over its corresponding
assembly.
Step 9: Insert the crankshaft (25) through the side
of power frame past the connecting rods (13) until it
rests in the crankshaft bearing cup (23) on the
opposite side, then tap in the opposite side
crankshaft bearing cup (23).
Step 10: Replace the inboard (21) and outboard
frame caps (35) using the same shim (22) stack that
was removed with each cap. Torque the hex head
bolts (18) to the proper load and check the
crankshaft (25) assembly.
Step 11: Apply a thin film of lubricant to crankshaft
(25) journals and connecting rod bearings (15) and
reattach to the crankshaft (25).
Be sure to torque the connecting rod bolts (17) to
the specification found in the Fits and Tolerances
Chart (Chart 3.0).
NOTE
First check to see that the connecting
rods (13) are not contacting the insides
of the crosshead (10). Then, check the
side to side end play per the
specifications in the Fits and Tolerances
Chart (Chart 3.0). Add or subtract shims
(22) as required.
Step 12: Install new crosshead seal cap gasket (9)
on crosshead stub seal cap (5) containing the new
crosshead stub oil seals (6) and place on the
crosshead (10) stub. Slide the crosshead seal caps
(5) to the power frame (1) and secure with hex head
bolts (8). Install crosshead stub deflectors (7) on the
crosshead assembly (10) stub.
Step 13: Reattach the crankcase cover (31) with
new crankcase cover gasket (32) using the hex
head bolts (30) to attach them.
Step 14: Replace the oil level indicator (28) and the
drain plug (27).
Step 15: Remove the oil fill plug (33), fill with the
recommended amount and type of oil, and replace
the oil fill plug (33). See Lubrication Chart (Chart
2.2) for recommendations and specifications for
each model power frame.
Step 16: Reconnect the plunger to the crosshead
assembly (10). TIGHTEN SECURELY, BUT DO
NOT OVER-TIGHTEN.
Step 17: It is recommended that the crankcase
breather (34) be cleaned during each oil change to
insure adequate air flow to the crankcase.

BD-60/85 POWER FRAME

FITS AND TOLERANCES
Crankshaft Bearing (23, 22) fit in Power Frame (1) .000 to .002
Crankshaft clearance (end play) without any preload .001 to .003
Connecting Rod Bearing (15) clearance over Crankshaft (25) .005 to .007
Crosshead Wrist Pin (12) clearance in Crosshead (10) .0005 to .0012
Crosshead Pin Bearing (14) clearance over Wrist Pin (12) .0020 to .0025
Crosshead (10) clearance in Power Frame (1) .004 to .007

CHART 3.0
 TORQUE SPECIFICATION CHART
FOR
BD-60/85 TRIPLEX PLUNGER PUMP

RECOMMENDED TORQUE
APPLICATION PART THREAD (LUBRICATED)
DESCRIPTION SIZE 1b-ft N-m

BD-60/ 85 CONNECTING ROD NUT 1/2-20UNF 43 58

POWER END*
FRAME CAP CAP SCREW 1/2-13UNC 35 47

CRANKCASE COVER CAP 3/8-16UNC 15 20

SCREW

STUB SEAL CAP SCREW 1/2-13UNC 35 47

PLUNGER-TO-STUB*** 9/16-12UNC 40 54

PLUNGER-TO-STUB 3/4-10UNC 75 102

CYLINDER TIE STUD NUT 3/4-10UNC 200 271

BD-60 No. 1-1/8 STUFFING BOX FLANGE 7/8-9UNC 300 407

or 7/8 FLUID NUT
CYLINDER**
DISCHARGE VALVE COVER/ 7/8-9UNC 300 407
CYLINDER HEAD NUT

BD-60 No. 1-3/4 STUFFING BOX FLANGE 7/8-9UNC 300 407

FLUID NUT
CYLINDER**
DISCHARGE VALVE COVER/ 3/4-10UNC 200 271
CYLINDER HEAD NUT

BD-60 No. 2-1/2 STUFFING BOX FLANGE 7/8-9UNC 300 407

FLUID NUT
CYLINDER**
DISCHARGE VALVE COVER/ 5/8-11UNC 110 149
VALVE COVER NUT

* APPLYS TO STANDARD CONSTRUCTION.

** APPLYS TO STANDARD STEEL CONSTRUCTION.

*** APPLYS TO BD-85 POWER FRAME FOR 1-1/8 & 7/8 CYLINDER ONLY.

CHART 3.1
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD-60 & BD-85 TRIPLEX PUMP POWER END
ITEM QTY PART NUMBER DESCRIPTION
REQ’D
B103232 Power End Assembly (for 1-3/4 & 2-1/2 Cylinder only)
B106073 Power End Assembly ( for 1-1/8 & 7/8 Cylinder only)
1 1 B100D0630100 Power Frame
2 2 B912137510A2 Alignment Pin
3 4 B824A0155013 Cylinder Tie Stud
4 4 B9108A121DF1 Cylinder Tie Stud Nut
5 3 B9410A15500A Crosshead Stub Seal Cap O-Ring
6 3 B141B1222300 Crosshead Stub Seal Cap
7 6 B9101A0806A1 Hex Head Cap Screw
7a 6 B9100W000278 Retaining Washer
8 6 B94111000150 Crosshead Stub Seal
9 3 B123A0603600 Crosshead Stub Deflector
10 3 B100419 Crosshead Assembly (for 1-3/4 & 2-1/2 Cylinder)
3 B100403 Crosshead Assembly ( for 1-1/8 Cylinder only)
11 6 B9137B0610A1 Crosshead Wrist Pin Set Screw
12 3 B119A0602700 Crosshead Wrist Pin
13 3 B100418 Connecting Rod Assembly (with Bearings)
14 3 B120A0794300 Crosshead Wrist Pin Bearing
15 3 B116B0639901 Connecting Rod Bearing
16 6 B9111AD800A2 Lockwasher
17 6 B9101E0824K5 Connecting Rod Bolt
18 1 B103D0603500 Crankshaft, 3.50” Stroke BD 85
19 2 B9610BAWA041 Crankshaft Main Bearing Cup
20 2 B9610CAWA001 Crankshaft Main Bearing Cone
21 1 B007434 Shim Set, Consisting of:
3 B134B0610001 Shim .020 (Yellow)
2 B134B0610002 Shim .010 (Brown)
2 B134B0610003 Shim .0075 (Clear)
2 B134B0610004 Shim .005 (Lt. Blue)
22 1 B133C0603600 Crankshaft Frame Cap--Inboard
23 12 B9101A0812A1 Hex Head Cap Screw
24 1 B94111000141 Crankshaft Oil Seal
25 1 B811B0323222 Key
26 1 B620B0608100 Crankcase Cover Gasket
27 1 B154B0606500 Crankcase Cover
28 14 B9101A0605A1 Hex Head Cap Screw
29 1 B920104A03D5 Nipple
30 1 B9205BAA4ED8 Reducing Tee
31 1 B9513ECAU0BB Oil Level Sight Gauge
32 1 B9214DA04JD5 Square Head Plug. Oil Drain
33 1 B9214DA06JD5 Square Head Plug, Oil Fill
34 1 B9514B1E0000 Crankcase Breather
35 1 B132C0603700 Crankshaft Frame Cap – Outboard
36 2 B9135A0404A1 Thumb Screw
37 1 B152C0687000 Plunger Cover

CHART 3.2
3.3 FLUID CYLINDER REMOVAL AND
DISASSEMBLY
See Section 1.2.6 Piping Design Considerations for
placement of quick connections to expedite fluid
cylinder maintenance.
Step 1: Remove inlet and outlet piping
connections to fluid cylinder (1).
NOTE
If the pump is equipped with a
lubricator, disconnect the lines going
to the stuffing boxes (50) before
proceeding.
Step 2: Remove the thumb screws and plunger
cover, and then disconnect the plunger (20) from the
crosshead assembly (not shown).
Step 3: Remove the four cylinder tie stud nuts
which secure the fluid cylinder (1) to the power
frame (not shown).
Step 4: Attach a sling and use a power lift to
separate the fluid cylinder (1) from the power frame.
Gentle prying may be required to separate the two
assemblies. Care should be exercised to avoid
shearing the two alignment pins (located on the front
of the power frame).
3.3.1 SUCTION/DISCHARGE
VALVE AND SEAT
REMOVEAL
Removal of the suction valves and seats can only be
accomplished after the removal of the plungers and
or the stuffing box assemblies.
Step 1: Remove the nuts (11) holding the stuffing
box flange (14) onto the fluid cylinder (1).
Step 2: Remove the threaded stuffing box gland
nut (19) from each stuffing box (15). Then lift off the
stuffing box flange (14).
Step 3: Carefully remove each stuffing box
assembly (15) and set to the side.
Step 4: Remove and discard all stuffing box
gaskets (13).
NOTE
Exercise care when removing these
gaskets (13) to avoid damaging the
gasket sealing area any time the
stuffing box (15) is removed. New
gaskets should be installed to assure a
positive seal.
Step 5: Remove the cylinder head and discharge
valve cover nuts (8), cylinder head and discharge
valve cover flanges (7), cylinder head extensions
(12), and discharge valve stops (6). Examine them
for wear. These parts can be reused if found to be
in acceptable condition.
Step 6: If this is an inspection only, remove the
valves (3) and springs (4) and mark each valve (3) to
be matched with the seat (2) from which it was
removed. Also, remove and discard the cylinder
head and discharge valve cover gaskets (5).
NOTE
Marking is essential during inspection
if the valves (3) are to be reused. In the
case of a complete rebuild, discard the
valves (3), seats (2) and springs (4).
CAREFULLY REMOVE THE CYLINDER
HEAD AND DISCHARGE VALVE
COVER GASKETS TO AVOID
DAMAGING THE GASKET SEAL
DECKS.
Step 7: Removal of the valve seats (2) requires
the use of a valve seat puller. All valve seats are a
press-fit and require a mechanism for applying
upward force from below the valve seat. A valve
seat puller is available for each fluid cylinder size.
Following the instructions with the valve seat puller,
remove the upper discharge valve seats (2) first, and
then remove the lower suction valve seats (2) from
the fluid cylinder (1).
NOTE
The suction valve seats must be
removed through the cylinder head
ports where each cylinder head
extension attaches. They cannot be
removed through the discharge ports
on top.
Step 8: Clean and inspect fluid cylinder (1) for any
damage or wear before installing new parts.
3.3.2 STUFFING BOX DISASSEMBLY
Step 1: Remove the stuffing box assembly (15)
from the stuffing box flange (14).
For non-lubricated stuffing boxes, follow Steps
2-4 below:
Step 2: For non-lubricated stuffing boxes, remove
the stuffing box gland nut (19), gland follower (18),
plunger (20), and packing (17).
Step 3: Clean and inspect the stuffing box (15)
bore to assure there is no pitting in the packing area.
Step 4: Clean and inspect the throat bushing (16)
and gland follower (18) to assure there is no pitting
or wear areas which could lead to premature
packing failure and replace as necessary. Inspect
the plungers (20) for pitting or longitudinal scoring
lines and replace as required.
For lubricated stuffing boxes, complete Step 1
above and follow with Steps 2-4 below:
Step 2: Remove the stuffing box gland nut (19),
gland follower (23), rear packing (17), lantern ring
(22), and front packing (17).
Step 3: Clean and inspect the stuffing box (21)
bore to assure there is no pitting in the packing area.
Step 4: Clean and inspect the throat bushing (16),
lantern ring (22), and gland follower (23) to assure
there is no pitting or wear areas which could lead to
premature packing failure and replace as needed.
Inspect the plungers (20) for pitting or longitudinal
scoring lines and replace as required.
3.4 FLUID CYLINDER ASSEMBLY
AND REPLACEMENT
WARNING
Precautions should be taken to prevent
foreign material from entering the
assembly when inspecting or replacing
components of the fluid cylinder (1).
Solid foreign debris contaminating the
assembly will lead to premature failure
of the valves (3) and seats (2).
3.4.1 ASSEMBLY OF STUFFING BOX
Step 1: Apply a thin film of rust inhibiting lubricant
to the inside bore of the stuffing box (15) or (21).
Step 2: Apply a thin film of rust inhibiting lubricant
to the throat bushing (16), gland follower (18), and
each packing ring (17). If assembling a lubricated
stuffing box, lubricate the lantern ring (22).
Step 3: Insert the throat bushing (16), checking to
insure it has seated all the way to the bottom of the
stuffing box (15) (50). Insert the packing (17) one
ring at a time and use the gland follower (18) to
move each ring to the bottom. DO NOT
COMPRESS THE PACKING OR HAMMER INTO
PLACE. Detailed information regarding packing can
be found in Section 3.5 below.
3.4.2 INSTALLATION OF SUCTION
AND DISCHARGE VALVE SEATS
Step 1: Install the new valve seats (2) by setting
the new valve seat with the radius edge to the seat
pocket. Then, place a round disc larger than the
seat on top of the end with a seat bevel on the inside
diameter and press into place. Install the lower
suction valve seats before installing the upper
discharge valve seats.
NOTE
Do not hammer valve seats (2) into the
fluid cylinder – press into place. Also,
check to insure that the valve seat (2) is
going in straight and not cocked at an
angle. Shrinking the seats (2) with dry
ice will make the installation process
easier.
Step 2: Examine valve seats (2) to be sure they
were not damaged in the pressing process and are
properly seated.
3.4.3 REASSEMBLY OF DISCHARGE
MANIFOLD
Step 1: Insert new valves (3) and check to see
that each valve (3) moves freely. Place the new
valve springs (4) on top of each valve.
Step 2: Inspect the gasket sealing deck area for
any gouges, dings, or pits; then install the new
cylinder head and discharge valve cover gaskets (5).
Step 3: If reusing the discharge valve stops (6),
clean and inspect for any gouges, dings, or pits that
would prevent the parts from properly sealing. Next,
place the discharge valve stop (6) over each valve
spring (4) with the small end down and the threaded
hole up.
Step 4: Replace the discharge valve cover (7) and
the nuts (8) to secure the assembly. Nuts (8) should
be torqued to the recommended load as shown in
the Torque Specification Table (Chart 3.1).
3.4.4 REASSEMBLY OF CYLINDER
HEAD (SUCTION SIDE)
Step 1: Insert new valves (3) and check to see
that each valve (3) moves freely. Place the new
valve spring (4) on top of each valve.
Step 2: Inspect the gasket sealing deck area for
any gouges, dings, or pits; then install the new
cylinder head gaskets (5).
Step 3: If reusing the cylinder head extensions
(12), clean and inspect for any cracks or excessive
wear and place the cylinder head extensions (12) in
the port at a slight angle in order to clear the top of
the valve spring (5).
3.4.5 MOUNTING FLUID CYLINDER
ASSEMBLY
Step 1: Attach a sling and use a power lift to
return the fluid cylinder (1) assembly to the power
frame. Insert the cylinder tie studs on the power
frame, through the holes provided on the stuffing
box flange (14) and carefully guide, but do not force,
the fluid cylinder (1) assembly onto the guide pins
located on the front of the power frame. Use the
cylinder tie stud nuts to secure the stuffing box
flange (14) to the power frame. Be sure to pull the
sides of the fluid cylinder up to the power frame
equally; avoid cocking at an angle as this could
shear the alignment pins.

Step 4: Place the previously repacked stuffing Step 2: Bring the plunger (20) and the crosshead
boxes (15) onto the fluid cylinder (1). Prior to stub together and thread the plunger (20) into the
installation, inspect the sealing face of the stuffing crosshead stub. TIGHTEN SECURELY, BUT
box (15) to insure there are no gouges, dings, or pits AVOID OVER TIGHTENING. REFER TO THE
to prevent proper sealing. TORQUE SPECIFICATIONS IN CHART 3.1 FOR
THE PROPER TORQUE LOAD.
Step 5: Replace the stuffing box flange (14) and
the nuts (11) to secure the assembly. Check to
insure all stuffing boxes (15) are flush with the fluid
cylinder (1). Nuts (11) should be torqued to the
recommended load as shown in the Torque
Specification Chart (Chart 3.1).

Step 6: Thread the stuffing box gland nut (19) into

the stuffing box (15). Stop when the stuffing box
gland nut (19) contacts the gland follower (18). Do
not tighten and compress the packing.

NOTE
It is recommended to apply an anti-
seize thread compound to the stuffing
box (15) thread and the stuffing box
gland nut (19) thread.

Step 7: Clean and inspect each plunger (20)

assembly. If there are pits, cracks, or longitudinal
scoring lines, discard and replace with new
plungers. Also, examine the plunger thread for any
thread damage before reconnecting to the
crosshead stub in the power frame.

Step 8: Apply a thin film of lubricant to the surface

of the plunger (20) and insert through the stuffing
box gland nut (19) into the gland follower (18) until
engaging the packing (17). Push, or lightly tap with
a rubber mallet, to drive the plunger (20) past the
packing (17).
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD- 60 TRIPLEX FLUID CYLINDER
NO. 1-3/4” CYNDER (UP TO 1.750” PLUNGER)

ITEM QTY PART NUMBER DESCRIPTION

REQ’D
1 1 B300D0601800 Fluid Cylinder, BD-60 1-3/4” (Bare)**
2 6 B322B0808700 Suction & Discharge Valve Seat
3 6 B320B0610500 Suction & Discharge Valve
4 6 B334B0717630 Suction & Discharge Valve Spring
5 6 B619A0608402 Discharge Valve Cover Gasket (Synthetic)
6 B619A0608402-1 Discharge Valve Cover Gasket (Copper)
6 B619A0836506 Discharge Valve Cover Gasket (Spiral Wound S.S.)
6 3 B370A0610600 Discharge Valve Stop
7 6 B317B0611400 Cylinder Head & Discharge Valve Cover Flange
8 24 B9108E121DF1 Valve Cover Stud Nut
9 24 B824A0155012 Valve Cover Stud
10 8 B824A0155125 Stuffing Box Flange Stud
11 8 B9108A141AM5 Stuffing Box Flange Stud Nut
12 3 B368C0609100 Cylinder Head Extension
13 3 B622B0647505 Stuffing Box Gasket (Spiral Wound S.S.)
14 1 B366C0609300 Stuffing Box Flange
15 3 Stuffing Box, Non-Lubricated (Steel) **
B337B0631900 To 1.375” Plunger
B337B0632000 To 1.750” Plunger
16 3 Throat Bushing (Cast Iron) **
B341A0604301 For 1.250” Plunger
B341A0604302 For 1.375” Plunger
B341A0604401 For 1.500” Plunger
B341A0604402 For 1.625” Plunger
B341A0604403 For 1.750” Plunger
17 3 Packing Set (As Specified By Customer)
18 3 Gland Follower (Cast Iron) **
B339A0623801 For 1.250” Plunger
B339A0623802 For 1.375” Plunger
B339A0623901 For 1.500” Plunger
B339B0623902 For 1.625” Plunger
B339B0623903 For 1.750” Plunger

* ITEM 1 INCLUDES 2, 3, 4, 8, 9, 10, & 11.

**OTHER MATERIALS AVAILABLE ON REQUEST.

CHART 3.3
(Continued on next page)
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD- 60 TRIPLEX FLUID CYLINDER
NO. 1-3/4 CYNDER (UP TO 1.75” PLUNGER)

ITEM QTY. PART NUMBER DESCRIPTION

REQ’D
19 3 Stuffing Box Gland (Steel) **
B338B0611501 To 1.375” Plunger
B338B0611502 To 1.750” Plunger
20 3 Plunger, Colmonoy Coated **
B353B0609601 1.250” Plunger
B353B0609602 1.375” Plunger
B353B0609603 1.500” Plunger
B353B0609604 1.625” Plunger
B353B0609605 1.750” Plunger
21 3 Stuffing Box, Lubricated (Steel) **
B337B0628901 To 1.375” Plunger
B337B0612901 To 1.750” Plunger
22 3 Lantern Ring (Cast Iron) **
B340A0604501 For 1.250” Plunger
B340A0604502 For 1.375” Plunger
B340A0604601 For 1.500” Plunger
B340A0604602 For 1.625” Plunger
B340A0604603 For 1.750” Plunger
23 3 Gland Follower (Cast Iron)**
B339A0604101 For 1.250” Plunger
B339A0604102 For 1.375” Plunger
B339A0604201 For 1.500” Plunger
B339A0604202 For 1.625” Plunger
B339A0604203 For 1.750” Plunger

** OTHER MATERIALS AVAILABLE ON REQUEST.

CHART 3.3
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD- 60 /85 TRIPLEX FLUID CYLINDER
NO. 2-1/2 CYNDER (UP TO 2.625” PLUNGER)

ITEM QTY PART NUMBER DESCRIPTION

REQ’D
1 1 B300D0601700 Fluid Cylinder, BD-60 2-1/2” (Bare)*
2 6 B322B0808600 Suction & Discharge Valve Seat
3 6 B320B0607500 Suction & Discharge Valve
4 6 B334B0616101 Suction & Discharge Valve Spring (Medium)
B334B0616102 Suction & Discharge Valve Spring (Heavy)
B334B0616103 Suction & Discharge Valve Spring (Light)
5 6 B619B0608401 Discharge Valve Cover Gasket (Synthetic)
B619B0608401-1 Discharge Valve Cover Gasket (Copper)
6 3 B370B0672300 Discharge Valve Stop
7 6 B317B0607200 Cylinder Head & Discharge Valve Cover
8 24 B9108A101DF1 Valve Cover Stud Nut
9 24 B824A0154910 Valve Cover Stud
10 8 B824A0155125 Stuffing Box Flange Stud
11 8 B9108A141AM5 Stuffing Box Flange Stud Nut
12 3 B368B0603800 Cylinder Head Extension
13 3 B622B0647507 Stuffing Box Gasket (Spiral Wound S.S.)
14 1 B366B0603900 Stuffing Box Flange
15 3 Stuffing Box, Non-Lubricated (Steel) **
B337B0626600 To 2.125” Plunger
B337B0632100 To 2.625” Plunger
16 3 Throat Bushing (Cast Iron) **
B341A0603301 For 1.875” Plunger
B341A0603302 For 2.000” Plunger
B341A0603303 For 2.125” Plunger
B341A0603001 For 2.250” Plunger
B341A0603002 For 2.375” Plunger
B341A0603003 For 2.500” Plunger
B341A0603004 For 2.625” Plunger
17 3 Packing Set (As Specified by Customer)

* ITEM INCLUDES ITMS 2, 3, 4 5, 8, 10, 11

** OTHER MATERIALS AVAILABLE UPON REQUEST

CHART 3.4
(Continued on next page)
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD- 60 85 TRIPLEX FLUID CYLINDER
NO. 2-1/2 CYNDER (UP TO 2.625” PLUNGER)

ITEM QTY PART NUMBER DESCRIPTION

REQ’D
18 3 Gland Follower (Cast Iron) **
B339B0624001 For 1.875” Plunger
B339B0624002 For 2.000” Plunger
B339B0624003 For 2.125” Plunger
B339B0624101 For 2.250” Plunger
B339B0624102 For 2.375” Plunger
B339B0624103 For 2.500” Plunger
B339B0624104 For 2.625” Plunger
19 3 Stuffing Box Gland Nut (Steel) **
B338B0607101 To 2.125” Plunger
B338B0607102 To 2.500” Plunger
B338B0607103 To 2.625” Plunger
20 3 Plunger, Colmonoy Coated **
B353B0625101 1.875” Plunger
B353B0625102 2.000” Plunger
B353B0625103 2.125” Plunger
B353B0625104 2.250” Plunger
B353B0625105 2.375” Plunger
B353B0625106 2.500” Plunger
B353B0625199 2.625” Plunger
21 3 Stuffing Box, Lubricated (Steel) **
B337B0606800 To 2.125” Plunger
B337B0606900 To 2.625” Plunger
22 3 Lantern Ring (Cast Iron)**
B340A0603201 For 1.875” Plunger
B340A0603202 For 2.000” Plunger
B340A0603203 For 2.125” Plunger
B340A0602901 For 2.250” Plunger
B340A0602902 For 2.375” Plunger
B340A0602903 For 2.500” Plunger
B340B0602904 For 2.625” Plunger
23 3 Gland Follower (Cast Iron) **
B339A0603101 For 1.875” Plunger
B339A0603102 For 2.000” Plunger
B339A0603103 For 2.125” Plunger
B339A0602801 For 2.250” Plunger
B339A0602802 For 2.375” Plunger
B339A0602803 For 2.500” Plunger
B339A0602804 For 2.625” Plunger

** OTHER MATERIALS AVAILABLE UPON REQUEST

CHART 3.4
 BEAR PUMP & EQUIPMENT, INC.
BILL OF MATERIAL
BD-60/85 TRIPLEX FLUID CYLINDER
NO. 1-1/8 CYLINDER (UP TO 1.125” PLUNGER)

ITEM QTY PART NUMBER DESCRIPTION

REQ’D
1 1 B300D0621700 Fluid Cylinder, BD-60 1-1/8” (Bare)*
2 6 B322B0824300 Suction & Discharge Valve Seat
3 6 B320B0836100 Suction & Discharge Valve
4 6 B334B0625600 Suction & Discharge Valve Spring
5 6 B619B0608406 Cylinder Head & Valve Cover Gasket (Copper)**
6 3 B370A0624900 Discharge Valve Stop
7 24 B9108E141AM5 Cylinder Head & Valve Cover Hex Nut
8 6 B317B0778000 Cylinder Head & Discharge Valve Cover
9 24 B824A0155115 Cylinder Head & Discharge Valve Cover Stud
10 8 B824A0155125 Stuffing Box Flange Stud
11 8 B9108A121DF1 Stuffing Box Flange Stud Nut
12 3 B368B0747600 Cylinder Head Extension
13 3 B622B0647502 Stuffing Box Gasket (Spiral Wound S.S.)**
14 3 B366C0637800 Stuffing Box Flange
15 3 B337B0675300 Stuffing Box, Non-Lubricated (Steel)**
16 3 Throat Bushing (Cast Iron)**
3 B341A0625402 For 1.000” Plunger
3 B341A0625404 For 1.125” Plunger
18 3 Gland Follower (Cast Iron) **
B341A0 For 1.000” Plunger
B341A0 For 1.125” Plunger
B341A0 For
19 3 B338A0625103 Stuffing Box Gland (Steel)**
20 3 Plunger (Colmonoy Coated Steel) **
B353B0657705 For 1.000” Plunger
B353B0657707 For 1.125” Plunger
21 3 B337B0675301 Stuffing Box, Lubricated (Steel)**
22 3 Lantern Ring (Cast Iron)**
B340 For 1.000” Plunger
B340 For 1.125” Plunger
23 3 Gland Follower
B339 For 1.000” Plunger
B339 For 1.125” Plunger

* ITEM 1INCLUDES ITEMS 2, 3, 4, 7, 8, 9, 10, & 11

** OTHER MATERIALS AVAILABLE UPON REQUEST

CHART 3.5

3.5 INSTRUCTIONS FOR PACKING
INSTALLATION & ADJUSTMENT
Plunger packing (17) replacement is best
accomplished after removal of the fluid cylinder (1)
from the power frame. See instructions for Fluid
Cylinder removal in Section 3.1 above.
The following instructions are for the three (3) most
common types of packing (17). Review the
exploded view (Illustration 3.1) and corresponding
parts listing (Chart 3.4) to correctly identify the
appropriate parts and their descriptive names. It is
important to adhere to the following instructions in
order to maximize the life of both the packing (17)
and the plunger (20).
3.5.1 INSTRUCTION FOR SQUARE
RING TYPE PACKING
Step 1: Remove the plunger (20) and stuffing box
gland nut (19).
Step 2: Remove the gland follower (18) or (23),
packing (17), and lantern ring (22), if lubricated.
Step 3: Clean all metal parts, including the inside
bore of the stuffing boxes (15) or (21).
Step 4: Inspect all metal parts for pitting,
excessive wear, and longitudinal scoring lines.
Plungers and stuffing box internal components
should be replaced when scoring is present.
Step 5: Refer to the Stuffing Box with Square
Packing Rings Chart (Chart 3.7) which follows, for
the proper arrangement of packing and components.
Step 6: Apply a film of light oil to the inside of the
stuffing box (15) or (21).
Step 7: Apply a film of light oil to each packing
(17) ring.
Step 8: Install the packing rings individually into
the stuffing box (15) or (21). Seat each ring firmly
into place. It may be helpful to use the gland
follower (18) or (23) to push the individual packing
rings to the bottom. DO NOT BEND, TEAR, OR
COMPRESS THE PACKING RINGS. Split ring type
packing should be installed with the splits located
120° apart. Refer to the Stuffing Box with Square
Packing Chart (Chart 3.7) for the proper number of
rings to be installed.
Step 9: If assembling a lubricated stuffing box
(21), apply a film of light oil to the lantern ring (22)
and install between the packing (17) rings as shown
in the Stuffing Box with Square Packing Chart (Chart
3.7). Be sure the lantern ring (22) aligns with the
lubrication port in the stuffing box (21).
Step 10: Install the gland follower (18) or (23) after
the last packing ring.
Step 11: Apply an anti-seize thread compound to
the stuffing box (15) or (21) threads and screw on
the stuffing box gland (19) until FINGER TIGHT.
Step 12: Apply a film of light oil to the plunger (20)
assembly and carefully install the plunger (20)
through the packing (17). Re-couple the plunger
(20) to the crosshead stub.
Step 13: Rotate the crankshaft in the proper
direction about 10 times. Unscrew the stuffing box
gland (19) and re-tighten to finger tight again. Be
sure the gland is only finger tight.
Step 14: The pump is now ready to run to “seat-in”
the packing (17). Start the pump and allow it to run
idle with little or no pressure. Do not be alarmed if
the packing (17) leaks. Leakage will decrease as
pressure is applied to the pump and as the packing
(17) begins to heat up. During the first 15 minutes of
operation, allow each packing set (17) to leak at
about 60-120 drops per minute. If necessary,
loosen the stuffing box gland (19) to maintain the
desired leak rate, but only if there is a reduction in
the leak rate during the first 15 minutes. As the
plunger (20) travels through the packing (17), the
packing may begin to heat up and it will need room
to expand. Increasing temperature due to
inadequate lubrication or over-tightening of the
stuffing box gland (19) will cause the packing (17) to
bind on the plunger (20) and result in premature
failure of the packing (17). To assure proper seating
of the packing (17), it is recommended that a light oil
be squirted on to the plunger (20) outside of the
stuffing box (15) or (21) during the packing seating.
Closely monitor the temperature, carefully by touch,
of the plunger (20) and the stuffing box (15) or (21).
Step 15: Slowly tighten the stuffing box gland nuts
(19) about 1/8 to 1/6 turn every 4-5 minutes until a
leak rate of 10-30 drops per minute per plunger (20)
is attained. If the plunger (20) or stuffing box (15)
(50) temperature increases due to the tightening,
loosen the glands and repeat Step 14. Continue
Step 14 until the temperature remains constant after
re-tightening the stuffing box glands (19).
NOTE
During normal operation, a slight leakage
of 10-30 drops per minute should be
accepted. This will allow the plunger (20)
to be lubricated and increase the life of
both the plunger (20) and packing (17).
When readjusting the packing (17), do
not over tighten. Tighten only as needed
to compensate for excessive leakage.
3.5.2 INSTRUCTIONS FOR MOLDED
‘V’ RING TYPE PACKING
Step 1: Remove the plunger (20) assembly.
Step 2: Remove the stuffing box gland (19), gland
follower (18) or (23), packing (17), and lantern ring
(22) if lubricated.
Step 3: Clean all metal parts, including the inside
bore of the stuffing boxes (15) or (21).
Step 4: Inspect all metal parts for pitting,
excessive wear, and longitudinal scoring lines.
Plungers and stuffing box internal components
should be replaced when scoring is present.
Step 5: Refer to the Stuffing Box with Molded “V-
Ring” Packing Chart (Chart 3.8) which follows, for
the proper arrangement of packing and components.
Step 6: Apply a film of light oil to the throat
bushing (16) and place in the stuffing box (15) or
(21). Make sure it is seated all the way to the
bottom.
Step 7: Apply a film of light oil to the inside of the
stuffing box (15) or (50) and to each packing (17)
ring.
Step 8: Install the packing (17) rings individually
into the stuffing box (15) or (21). Seat each ring
firmly into place. It may be helpful to use the gland
follower (18) or (23) to push the individual rings to
the bottom. DO NOT BEND, TEAR, OR
COMPRESS THE PACKING RINGS. Split ring type
packing should be installed with the splits located
120° apart. Refer to the Stuffing Box with Molded
“V” Ring Packing Chart (Chart 3.8) for the proper
number of rings or stack height to be installed.
Stack height is more important than the number of
rings. Install the male adapter ring first with the flat
side to the throat bushing (16) and seat it firmly.
The “V” seal rings must be installed with sealing lips
facing downward to the “pressure side” and the point
facing up. Seat the female adapter ring against the
last “V” seal ring.
Step 9: If assembling a lubricated stuffing box
(21), apply a film of light oil to the lantern ring (22)
and install between the packing (17) rings as shown
in the Stuffing Box with Molded “V” Ring Packing
Chart (Chart 3.8). Be sure the lantern ring (22)
aligns with the lubrication port in stuffing box (21).
Please note that each packing set (17) on either side
of the lantern ring (22) has its own male and female
adapter rings.
Step 10: Install the gland follower (18) or (23) after
the last packing ring.
Step 11: Apply an anti-seize thread compound to
the stuffing box (15) or (21) and screw on the
stuffing box gland (19) until FINGER TIGHT.
Step 12: Apply a film of light oil to the plunger (20)
assembly and carefully install the plunger (20)
through the packing (17). Re-couple the plunger
(20) to the crosshead stub.
Step 13: Rotate the crankshaft in the proper
direction about 10 times. Unscrew the stuffing box
gland (19) and re-tighten to finger tight again. Be
sure the gland is only finger tight.
Step 14: The pump is now ready to run to “seat-in”
the packing (17). Start the pump and allow it to run
idle with little or no pressure. Do not be alarmed if
the packing (17) leaks. Leakage will decrease as
pressure is applied to the pump and as the packing
(17) begins to heat up. During the first 15 minutes of
operation, allow each packing set (17) to leak at
about 60-120 drops per minute. If necessary,
loosen the stuffing box gland (19) to maintain the
desired leak rate, but only if there is a reduction in
the leak rate during the first 15 minutes. As the
plunger (20) travels through the packing (17), the
packing may begin to heat up and it will need room
to expand. Increasing temperature due to
inadequate lubrication or over-tightening of the
stuffing box gland (19) will cause the packing (17) to
bind on the plunger (20) and result in premature
failure of the packing (17). To assure proper seating
of the packing (17), it is recommended that a light oil
be squirted on to the plunger (20) outside of the
stuffing box (15) or (21) during the packing seating.
Closely monitor the temperature carefully by touch,
of the plunger (20) and the stuffing box (15) or (21).
Step 15: Slowly begin to tighten the stuffing box
gland nuts (19) about 1/8 to 1/6 turn every 4-5
minutes until a leak rate of 10-30 drops per minute
per plunger (20) is attained. If the plunger (20) or
stuffing box (15) or (21) temperature increases due
to the tightening, loosen the glands and repeat Step
14. Continue Step 14 until the temperature remains
constant after adjusting the stuffing box glands (19).
NOTE
During normal operation, a slight leakage
of 10-30 drops per minute should be
accepted. This will allow the plunger (20)
to be lubricated and increase the life of
both the plunger (20) and packing (17).
When readjusting the packing (17), do
not over tighten. Tighten only as needed
to compensate for excessive leakage.
3.5.3 INSTRUCTIONS FOR NON-
ADJUSTABLE PACKING
Step 1: Remove the plunger (20) assembly.
Step 2: Remove the stuffing box gland (19), gland
follower (23), packing (17), and lantern ring (22).
Step 3: Clean all metal parts, including the inside
bore of the stuffing boxes (21).
Step 4: Inspect all metal parts for pitting,
excessive wear, and longitudinal scoring lines.
Plungers and stuffing box internal components
should be replaced when scoring is present.
Step 5: Refer to the Stuffing Box with Non-
Adjustable Packing Chart (Chart 3.9) which follows,
for the proper arrangement of packing and
components.
Step 6: Apply a film of light oil to the inside of the
stuffing box (21) and to each packing (17) ring.
Step 7: Install the packing (17) rings individually
into the stuffing box (21). Be sure to install the
packing rings in the proper sequence. Refer to the
Stuffing Box with Non-Adjustable Packing Chart
(Chart 3.7). Make sure the lips on the seal rings
face the pressure and seat each ring firmly. It may
be helpful to use the gland follower (23) to push the
individual rings to the bottom. DO NOT BEND,
TEAR, OR COMPRESS THE PACKING RINGS.
Step 8: If assembling a lubricated stuffing box
(21), apply a film of light oil to the lantern ring (22)
and install between the packing (17) rings as shown
in the Stuffing Box with Non-Adjustable Packing
Chart (Chart 3.9). Be sure the lantern ring (22)
aligns with the lubrication port in stuffing box (21).
Step 9: Install the gland follower (23) after the last
packing ring.
Step 10: Apply an anti-seize thread compound to
the stuffing box (21) and screw on the stuffing box
gland (19) until FINGER TIGHT.
Step 111: Apply a film of light oil to the plunger (20)
assembly and carefully install the plunger (20)
through the packing (17). Re-couple the plunger
(20) to the crosshead stub.
Step 12: Rotate the crankshaft in the proper
direction about 10 times. Unscrew the stuffing box
gland (19) and screw back on until finger tight, then
tighten the stuffing box gland nut (19) with a spanner
wrench 1/8 to 1/6 turn. This is non-adjustable
packing; therefore, the glands should be tight at all
times. This keeps the packing from moving in the
stuffing box (21). After the pump has been running
under pressure for 2 or 3 hours, check the stuffing
box glands (19) again to make sure they have not
backed off.
Step 14: Check and tighten, if necessary, the
stuffing box gland (19) each day for the first 2 or 3
days until the packing (17) is completely seated.
Always tighten the glands while pump is running
under pressure with properly sized spanner wrench.
NOTE
Oil lubrication is mandatory for the majority of
non-adjustable packing assemblies. Certain new
materials in this type of packing will give
excellent non-lubricated service. Any system
which insures a dependable drip or flow of oil on
the plunger (20) either internally or on the
outside of the stuffing box (21) is desirable. Two
types of oil that work extremely well in
reciprocating pump applications are rock drill oil
and steam cylinder oil. The amount of oil
needed for lubrication can be found in the Drip
Lubrication Rate Chart (Chart 3.6)
DRIP LUBRICATION
RATE CHART
PLUNGER SIZE DRIPS/MINUTE
Up to 1-1/2” 8-10
1-1/2” to 2-1/2” 12-14
2-1/2” to 3-1/2” 16-18
3-1/2” to 4-1/2” 20-22
CHART 3.6
 STUFFING BOX FOR BD-60/ 85 AND BQ-100
WITH
SQUARE PACKING

C C
H

G D J F D
G
E J
A = PLUNGER DIA. (PACKING I.D.) A = PLUNGER DIA. (PACKING I.D.)
B = BOX DIA. (PACKING O.D.) B = BOX DIA. (PACKING O.D.)

NO. NO.
CYL
NO. A B C D G J RINGS
DIM. D
CYL
NO. A B C D E F G H J RINGS
DIM. F DIM. D

1 1 3 7 1 7 1 1 3 5 5 15 1 3 1
22 38 416 18 4 216 6 22 38 416 8 18 16 4 28 116 3 2
3 1 3 7 1 7 3 1 3 3 1 1 1 3 1
28 38 416 18 4 216 5 28 38 416 4 12 18 4 28 1 16 3 2
1 1 1 3 3 1 7 1 1 1 3 7 1 5 1 3 1
22 24 38 416 216 4 216 5 22 24 38 416 8 14 1 16 4 28 116 3 2
1 3 3 7 1 7 1 3 3 5 5 15 1 3 1
28 24 416 18 4 216 6 28 24 416 8 18 16 4 28 116 3 2
3 3 7 1 7 3 3 3 1 1 1 3 1
2 24 416 18 4 216 5 2 24 416 4 12 18 4 28 116 3 2
7 3 3 3 1 7 7 3 3 7 1 5 1 3 1
18 24 416 216 4 216 5 18 24 416 8 14 1 16 4 28 116 3 2
3 3 3 7 1 7 3 3 3 5 5 15 1 3 1
14 28 416 18 4 216 6 14 28 416 8 18 16 4 28 116 3 2
5 3 3 7 1 7 5 3 3 3 1 1 1 3 1
18 28 416 18 4 216 5 18 28 416 4 12 18 4 28 1 16 3 2
3 1 3 3 3 1 7 3 1 3 3 7 1 5 1 3 1
14 12 28 416 216 4 216 5 14 12 28 416 8 14 116 4 28 116 3 2
3 3 7 1 7 3 3 5 5 15 1 3 1
18 2 416 18 4 216 6 18 2 416 8 18 16 4 28 116 3 2
1 3 7 1 7 1 3 3 1 1 1 3 1
14 2 416 18 4 216 5 14 2 416 4 12 18 4 28 116 3 2

CHART 3.7
 STUFFING BOX BD-60/ 85 AND BQ-100
WITH
MOLDED "V" PACKING

C C
H

G D J F D
G
E J
A = PLUNGER DIA. (PACKING I.D.) A = PLUNGER DIA. (PACKING I.D.)
B = BOX DIA. (PACKING O.D.) B = BOX DIA. (PACKING O.D.)
* PLUS MALE AND FEMALE ADAPTOR RINGS * PLUS MALE AND FEMALE ADAPTOR RINGS
*NO. *NO.
CYL
NO. A B C D G J RINGS
DIM. D
CYL
NO. A B C D E F G H J RINGS
DIM. F DIM. D

1 1 3 7 1 7 1 1 3 13 5 1 3 1
22 38 416 18 4 216 7 22 38 416 16 18 1 4 28 116 3 2
3 1 3 7 1 7 3 1 3 15 1 3 1 3 1
28 38 416 18 4 216 6 28 38 416 16 12 116 4 28 116 3 2
1 1 1 3 3 1 7 1 1 1 3 1 1 5 1 3 1
22 24 38 416 216 4 216 6 22 24 38 416 116 14 116 4 28 116 3 2
1 3 3 7 1 7 1 3 3 13 5 1 3 1
28 24 416 18 4 216 7 28 24 416 16 18 1 4 28 116 3 2
3 3 7 1 7 3 3 15 1 3 1 3 1
2 24 416 18 4 216 6 2 24 416 16 12 116 4 28 116 3 2
7 3 3 3 1 7 7 3 3 1 1 5 1 3 1
18 24 416 216 4 216 6 18 24 416 116 14 116 4 28 116 3 2
3 3 3 7 1 7 3 3 3 13 5 1 3 1
14 28 416 18 4 216 7 14 28 416 16 18 1 4 28 116 3 2
5 3 3 7 1 7 5 3 3 15 1 3 1 3 1
18 28 416 18 4 216 6 18 28 416 16 12 116 4 28 116 3 2
3 1 3 3 3 1 7 3 1 3 3 1 1 5 1 3 1
14 12 28 416 216 4 216 6 14 12 28 416 116 14 116 4 28 116 3 2
3 3 7 1 7 3 3 13 5 1 3 1
18 2 416 18 4 216 7 18 2 416 16 18 1 4 28 116 3 2
1 3 7 1 7 1 3 15 1 3 1 3 1
14 2 416 18 4 216 6 14 2 416 16 12 116 4 28 116 3 2

CHART 3.8
STUFFING BOX FOR BD-60 AND BQ-100
WITH
NON-ADJUSTABLE PACKING

C
H

F D
G
E J
A = PLUNGER DIA. (PACKING I.D.)
B = BOX DIA. (PACKING O.D.)
* PLUS MALE AND FEMALE ADAPTOR RINGS
* NO.
CYL
NO. A B C D E F G H J RINGS
DIM. F DIM. D

1 1 3 9 5 1 1 3 1
22 38 416 16 18 18 4 28 116 2 1
3 1 3 9 1 1 1 3 1
28 38 416 16 12 18 4 28 116 2 1
1 1 1 3 5 1 1 1 3 1
22 24 38 416 8 14 14 4 28 116 2 1
1 3 3 9 5 1 1 3 1
28 24 416 16 18 18 4 28 116 2 1
3 3 9 1 1 1 3 1
2 24 416 16 12 18 4 28 116 2 1
7 3 3 5 1 1 1 3 1
18 24 416 8 14 14 4 28 116 2 1
3 3 3 9 5 1 1 3 1
14 28 416 16 18 18 4 28 116 2 1
5 3 3 9 1 1 1 3 1
18 28 416 16 12 18 4 28 116 2 1
1 1 3 3 5 1 1 1 3 1
13 12 28 416 8 14 14 4 28 116 2 1
3 3 9 5 1 1 3 1
18 2 416 16 18 18 4 28 116 2 1
1 3 9 1 1 1 3 1
14 2 416 16 12 18 4 28 116 2 1

CHART 3.13
CHART 3.9
SECTION 4.0

ENGINEERING

DATA
 ENGINEERING DATA SHEET
MODEL BD-60 / BD-85
3” STROKE-5450 POUND FRAME (PLUNGER) LOAD

CYL.. PLUNGER STUFFING DISPLACE- MAXIMUM SUCTION AREA DISCHARGE PERCENT CYLINDER MAXIMUM
SIZE DIAMETER BOX BORE MENT IN DISCHARGE VALVE THROUGH VALVE VALVE AREA DESIGN HYDROSTATIC
(I.D.) (GAL./REV) PRESSURE SIZE VALVE SEAT SIZE SUCTION & PRESSURE TEST PRESSURE
(PSIG) SUCTION & DISCHARGE (PSI)
DISCHARGE

1-1/8 1 1-5/8 .0306 6,900 1-5/16 .785 1-5/16 100 7,000 10,500

1-1/8 1-5/8 .0387 5,450 1-5/16 .785 1-5/16 79 7,000 10,500

1-3/4 1-1/4 2 .0476 4,400 2 2.07 2 169 4,500 6,750

1-3/8 2 .0579 3,650 2 2.07 2 139 4,500 6,750

1-1/2 2 .0689 3,000 2 2.07 2 117 4,500 6,750

1-5/8 2-3/8 .0808 2,600 2 2.07 2 100 4,500 6,750

1-3/4 2-3/8 .0937 2,250 2 2.07 2 86 4,500 6,750

2-1/2 1-7/8 2-3/4 .1076 1,960 2-7/16 3.54 2-7/16 128 2,000 3,000

2 2-3/4 .1224 1,725 2-7/16 3.54 2-7/16 113 2,000 3,000

2-1/8 2-3/4 .1382 1,525 2-7/16 3.54 2-7/16 100 2,000 3,000

2-1/4 3-1/8 .1549 1,360 2-7/16 3.54 2-7/16 89 2,000 3,000

2-3/8 3-1/8 .1762 1,220 2-7/16 3.54 2-7/16 80 2,000 3,000

2-1/2 3-1/8 .1913 1,100 2-7/16 3.54 2-7/16 72 2,000 3,000

2-5/8 3-1/8 .2109 1,000 2-7/16 3.54 2-7/16 65 2,000 3,000

Connections on Both Sides of Cylinder:

Size 1-1/8: 2” FNPT Suction Size 1-3/4: 2-1/2” FNPT Suction Size 2-1/2: 3” FNPT
Suction
1-1/4” FNPT Discharge 1-1/2” FNPT Discharge 2” FNPT
Discharge

CHART 4.0
 RECIPROCATING PUMP
COMPARATIVE FLOW RATE CURVES
160%
150%
140%
130%
PERCENT OF AVERAGE FLOW RATE (VELOCITY) IN DISCHARGE LINE

120%
110%
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
DUPLEX, SINGLE-ACTING

107%
100%
90%
82%

TRIPLEX, SINGLE-ACTING

100% 102%
95%
QUINTUPLEX, SINGLE-ACTING

0° 90° 180° 270° 360°

45° 135° 225° 315°

DEGREES OF CRANKSHAFT ROTATION

NOTE: The above curves are approximate and represent reciprocating pumps with a
connecting rod length equal to five times the crank throw.

CHART 4.1
 TRIPLEX AND QUINTUPLEX
RECIPROCATING PUMP SPEED - TORQUE CURVES

160
150
140
130
% OF FULL-LOAD TORQUE

120
110 (A) FULL-LOAD TORQUE

100
90
80
70
60
50
40
30
20 (B) NO-LOAD TORQUE

10
0
0 10 20 30 40 50 60 70 80 90 100
% OF FULL-LOAD SPEED

(A) FULL-LOAD TORQUE

This represents start-up against the designed discharge pressure of
the pump.

(B) NO-LOAD TORQUE

This represents start-up with an open by-pass valve to the pump
suction.

CHART 4.2
 BD-60 / BD-85

STANDARD MATERIALS & CONSTRUCTION

POWER END

COMPONENT MATERIAL

Power Frame ASTM A536 Grade 65-45-12 Ductile Iron

Crankshaft ASTM A536 Grade 80-55-06 Ductile Iron
Connecting Rod ASTM A536 Grade 80-55-06 Ductile Iron
Crosshead ASTM A48 Class 30 Cast Iron HT501
Crosshead Stub ASTM A564 Type 630 Annealed
Main Bearing Timken Tapered Roller
Connecting Rod Bearing Babbitt Lined Steel--Precision Automotive Type
Crosshead Wrist Pin ASTM A534 Grade 8620 CHT 203
Crosshead Wrist Pin Bearing SAE #660 Bearing Bronze/ASTM B438 Gr. 1 Type II
Crankcase Cover Commercial Quality Steel
Plunger Cover Commercial Quality Steel
Crosshead Stub Cap ASTM A108-1215 C.F. Carbon Steel
Crankshaft Cap ASTM A48 Class 30 Cast Iron
Lubrication Splash & Gravity

FLUID END

COMPONENT MATERIAL

Fluid Cylinder ASTM A516 Grade 70 Pressure Vessel Plate

Stuffing Box ASTM A108-1215 C.F. Carbon Steel
Throat Bushing ASTM A108-1117 C.F. Carbon Steel
Lantern Ring ASTM A108-1117 C.F. Carbon Steel
Gland Follower ASTM A108-1117 C.F. Carbon Steel
Gland Nut ASTM A108-1215 C.F. Carbon Steel
Plunger ASTM A108-1018 C.F. Coated Colmonoy #6
Valve ASTM A564 Type 630 Condition H1025
Valve Seat ASTM A564 Type 630 Condition H900
Valve Spring ASTM A313 Type 302 HT 303 Spring Wire
Valve Stops ASTM A108-1215 C.F. Carbon Steel
Flanges ASTM A108-1018 C.F. Carbon Steel
Bolting ASTM A193-79A Grade B7
Packing & Gaskets Per Application

NOTE: Special construction and or metallurgy available as dictated by operating conditions or customer
request.
CHART 4.3
 PUMPING TEMPERATURES AND FRAME LOADINGS

Listed below are the maximum reciprocating power pump fluid end operating temperatures for the standard fluid
end designs.

Frame loadings are also listed for the corresponding pumps.

MAXIMUM TEMP.
WITH WATER
MAXIMUM TEMP COOLED FRAME LOADING
PUMP MODEL STANDARD PUMP STUFF. BOXES (POUNDS) .

CX – 5 300° Not Designed 2000

BX – 10 300° Not Designed 2000
BD – 28 300° Not Designed 3000
BD – 30 260° 360° 1 2825
BD – 60 260° 360° 5425
BQ – 100 260° 260° 5425
BD – 120 260° Not Designed 9500
BD – 150 260° Not Designed 11900
BD – 160 260° Not Designed 12900
BX – 50 260° 340° 2 4600
BX – 70 260° 340° 2 5500
BX – 90 260° 340° 6500
BX – 115 260° 340° 3 8200
BX – 125 260° 300° 3 10000
BX – 150 260° 300° 4 12000
BX – 200 260° 300° 4 12000
BX – 300 200° 200° 4 12000

1. Water cooled Stuffing boxes available only on #1-1/2 cylinder.

2. Water cooled stuffing boxes available only on #2-1/2 cylinder

3. Water cooled stuffing boxes not available on #4 cylinder.

4. Water cooled stuffing boxed not available on #5 cylinder.

CHART 4.4