OPERATION MANUAL FOR LGF-500 Drilling Pump

CONTENTS

1 Introduction ……………………………………………………………………..……..….……3

2 Technical specification and performance parameters ……………………………………..4

3 Installation of new pump…………………………………………………………………….. ..6

4 Requirements for suction system …………………………………………………..……… 10

5 Preparation of power end ………………………………………………………………..…..11

6 Spray pump assembly …………………………………………………………...…………...14

7 Assembly of fluid end parts …………………………………………………………………. 17

8 Lubrication …………………………………………………………………………………. …23

9 Maintenance ………………………………………………………………………………..…29

10 Daily maintenances of Pump ………………………………………………………………45

11 Possible failures and how to eliminate them……………………………………………...48

12 Long Term Storage …………………………………………………………..………….....49

13 Special Tools List For LGF-500 Mud Pump, delivered together with the pump….......50
14 Spare Parts Lift For LGF—500 Mud Pump, delivered together with the pump….. ….51

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

The mud pump LGF-500, manufactured by our company, has been completely assembled and

test-operated under full load and then all lube oil has been discharged from power end before being

delivered to our customers. The pump must be checked and operated according to the following

methods and measures before being put into formal services. In order to prevent personal injury during

the performance of any checking and maintenance processes, it must be shut down and not operating,

all safety and protection facilities installed on the prime mover and drive device should be put in safe

positions.

3.1、Setting of Pump
The skid under the LGF-500 pumps is fit for all types of installations, but it is worth to be

mentioned that although the frame with box structure at the power end has high resistances to bending,

but relatively lower resistances against twist; therefore, the supports under the frame must be level and

with enough strength to bear the pump’s dead load and dynamic forces exerted upon during operation.

3.2、Land Installation
In land installation, it is suggested that a mat base with, at least, eight pieces of 3″×12″

（76mm×305mm）boards be placed under the pump skids along the entire length， the positions as

shown in the Figure 2. The board under the pump skids must, at least, be 12″（305mm）wider than the

width of the pump skid runner. More solid foundations are required in case of the installation being

located in wet or swampland.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Fig. 2

3.3、Permanent Installations
While the pump being permanently installed on the structural base or concrete slab on a barge or

drilling platform and the pump skid being fixed by bolts, it is essential that the skid be properly shimmed

to prevent the power frame from possible distortion or twists. The pump skid must be solidly sat down

on all shims when all bolts are tightened.

In case of barge installation, the pump skid is usually bolted to T-beam, the positions for installing shims

are shown in the Figure 2 and 3. Properly shimming should be noted to avoid possible twist or distortion.

All shims must exceed the full width of the skid beam flanges and have a minimum length of 12”

(305mm).

When integral installations for power unit or electric motor and pump skids are required， the pump

must be fixed on the skids of the T beam, with retention blocks rather than bolts； in this way， the

pump could be a bit “floating” so as to reduce greatly the possible deformation of the pump frame

caused by the deformation of barge deck or platform.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Pump skid

Shim

T-beam Deck

Fig 3

3.4、Installation of Drive
Whether to use V- belt or multi-strand chain or universal shaft for the drive between power source and

the pump, it must be very careful during the whole installation to ensure the longest service life and

minimize the shut- downs caused by failures from the drive.

Upon installation of drive sheave or sprocket, make sure all rust preventatives or greases in the hub

and on the shaft are removed；burrs and rough spots on the keys，keyways and shaft must be removed

so that all keys fit properly in the keyways on the shaft and drive elements. The shaft of the pinion gear

should be coated with light lube oil or anti-sticky oil, and then fit the hub of sheave or sprocket, tighten

all bolts according to the following requirements:

Tightening bolts with wrench or wrench with extension pipe may lead to exceeding torque, therefore, it

is imperative to adhere to the torque value given in the following table to tighten all bolts; otherwise, it

may damage the hub and the sheave by the excessive tightening force, which is again multiplied by the

wedging action of the tapered surface. In addition, all bolts of hub must be tightened alternately and

gradually.
Table Ⅲ
Wrench Length Force on wrench
Pump Model Hub Spin up Torque
300 ft.Ibs 30″ 120Ibs
LGF—500 W
(406N.m) （760mm） (534N)

3.4.1 V-belt drive

3.4.1.1 Checking sheave groove status
Before installation, check that the sheave groove is not worn out and getting rounded, otherwise, the

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

V-belt will be damaged quickly. The groove sidewall must be level and straight and there are no

contaminants, extrusions or protrusions inside.

3.4.1.2 Checking sheave alignment
Having installed all sheaves and tightened them to working status check their alignment. If the

distances from one side of the two sheaves to the centerline of sheave groove are equal, check the

alignment with two tightened strings (for fishing or better for piano) along one side of the two sheaves;

one is put above the sheave center and another below the center, and then move one of two sheaves

until the strings have touched 4 points of the sheave rim; in this way determining the two centerlines of

the drive sheaves are parallel and their side faces are perpendicular to their axle lines.

3.4.1.3 Adjustment of V-belt Preset Tension Force

To adjust the belt tension, change/increase the center-to-center distance between two sheaves until no

sag to be found on the belt tightening side, and the slack side is also tightened but has a bit of sags.

And then increase center-to-center distance a little more, for example, if the center distance is 100”

(2540mm), 1/2” (13mm) is to be increased after adjustment of the center-to-center distance; again if the

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

Note: Don’t obtain belt tension by lifting the pump or by lowering the pump below ground level to allow

the belt to be tensioned by pump’s weight.

3.4.2 Chain drive

3.4.2.1 Installation
Installation and maintenances correctly are important means to extend the service life of chain

drive and chains and sprockets themselves. Many factors such as the width of chain, center distance,

speed and load etc. are to be considered when determining the allowable alignment tolerance of

sprockets; since there is no perfect “operating method” to be applied, therefore, what we can do is to

make the chain alignment as exactly as possible. As mentioned above in 3.4.1.2, a more precise

alignment can be made with two stretching steel wires (better for piano) along one side of the both

sprockets; one is put above the centerline and another below the centerline, and then move one of two

sprockets until the strings have touched 4 points of the sprocket rim; in this way, to determine the two

centerlines of sprockets are parallel and their end faces be perpendicular to their axle lines.

3.4.2.2 Lubrication of chain drive

The lubrication system used for all chain drive in LGF series pumps is an independent one, which has

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

its own lube oil pump, reservoir and drive. Filling the lube oil into the chain case must be up to the

indicated height. The lube oil to be used is as follows:

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

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

If Ambient temperature below 0°F （ -18°C ） , Please consult a reputable lube oil dealer for

recommendations. As for those approved lube-oil specifications and their supplements, references

might be made to the reports/bulletins usually used on lube oil, which are written and published by

oil-manufacturer. If there is any discrepancy between manual and the reports/bulletins, the suggestion

from the reports/bulletins shall be prevailed.

Owing to the chain lube system being an independent system, the maintenance must be carried

out based on equipment’s special requirements, which include:

 Daily checking oil level

 Daily checking oil status

 Daily checking oil pressure (（5～15psi）

（ 0.035～0.103MPa）

 Supplying some oils to chain

 Checking nozzle’s working status on the spray tube

 Checking the working conditions of the oil pump’s drive (V-belts, or chain)

Note:

a. There is a pressure relief adjusting screw on the rear of the pump housing to adjust the oil

pressure.

b. When oil pressure is too high or too low, which indicate that the suction and discharge filter

screens need to be cleaned

4. Requirements for Suction System

The design of pump suction system has been considered to install the system independently. To obtain

a satisfied suction performance, the LGF series pumps must have positive head (pressure); the

optimum pressure for suction manifold is 20～30psi （0.14～0.21Mpa）. Under this pressure, the pump

could have the maximum volumetric efficiency and the longest service life for consumable parts. This

pressure can be obtained by 5×6 charging pump with a 40 hp, 1150-rpm electric motor. A special kind

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

of device is necessary to keep the charging pump and the triplex pump automatically and

synchronously turned on and off. For drilling rigs driven by DC motor, usually a signal sending out from

DC control panel actuates the electromagnetic starter; at this time, the air line of drilling pump clutch

can provide a group of contactors when clutch is engaged, through which supply power to the

electromagnetic starter.

The suction pipeline should be arranged with a by pass for the charging pump, to facilitate the drilling

pump’s continuous operation when the charging pump is in maintenance or failure. When the drilling

pump is operated without charging pump, usually replace a softer suction valve spring to improve

suction performances.

Suction stabilizer is a very efficient supplementary device, which can fully charge the fluid into cylinder

liner and greatly eliminate the fluid fluctuations in suction pipes resulting in a smoother flow in the

discharge line.

Note: Don’t connect the discharge pipe of the safety valve to the suction pipeline, since when

the safety valve opens it causes a sudden rise to the system internal pressure; if the pressure is

higher than the rated pressure of the system, it will damage the manifold, suction stabilizer and

centrifugal pump etc.

5. Preparation of Power End

Before being shipped to the users, the LGF series pump manufactured by our company has been

completely assembled and test operated. All lube oils have been drained. Before operating the pump,

the following operations and checks must be carried out.

5.1 Power End Lubrication

Before filling lubricant, open inspection window on cover and check power end oil reservoir for possible

accumulation of condensation, and drain and flush the inner chamber by removing the pipe plugs on

each side of the pump (see item 2, Fig.7). Fill in the proper brand and quantity of lubrication oil in the

power end according to the requirements specified on the designation plate of pump frame.

Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down for about 5

minutes until oil stabilized, check oil level gauge (see item 1, Figure 7). It is usually necessary for a few
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

more gallons (10 liters) of oil to be added due to a certain amount being retained in the crosshead and

frame cavities.

Note：When the pump is first put into operation or is reused after a long time storage, in

addition to checking pump as per above mentioned requirement, prior to operation, the

inspection hole cover and crosshead bore cover must also be opened to refill sufficient lube oil

into crank shaft, pinion shaft bearings, oil chamber, moving engagement surfaces of cross head

guide sleeve, oil groove of guide sleeve, etc, to lubricate all moving and frictioning surfaces of

the pump.

5.2 Installation of Crosshead Intermediate Rods and

Diaphragm Stuffinging Box for LGF-500 Pump
As shown in Figure 4, remove the diaphragm stuffing box (1) and rotate pump crankshaft so that

crosshead is at the front of the stroke, thoroughly clean the crosshead front and the end face of the

intermediate rod; and then insert the alignment boss of intermediate rod into crosshead bore and

tight the bolts (2) with the torque of 150-170ft.lbs (203-230 N.m), finally lock it with steel wire.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Fig. 4
Completely clean surface of guide sleeve（3）and stuffing box（1）, then fix “O”ring（4）and stuffing

box as well as connector (5) on oil return line. Tight stuffing box by use of torque below and connect

with oil return pipeline（6）.

12-14ft.lbs (16-19 N.m)

Inside stuffing box there are dual lip oil seal（7）, seal ring（8）,“O”ring（9）, lock spring（10）

and“O”ring（11）.Installation is as follows：

1）Take away spring (7a) from dual lip oil seal（7），and fix the oil seal onto the external surface of

intermidiate rod with the main seal lip being facing power end . Then fit spring（7a）into seal lip and

slide the seal into stuffing box.

Note ： Single lip oil seal may be used to take the place of dual lip oil seal(7) near power end.

However, it cannot be used in outside location (fluid end).

2）Install the O-ring (11) into oil seal ring (8), put the seal over the intermediate rod and then slide
it into the stuffing box bore.

3）Install the O-ring (9) into the groove of the stuffing box.
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

4）Install the dual lip oil seal at right side (7) in Figure 4, the method is the same as item 1)
5）Install lock spring (10) with its opening facing downwards.

Note ： Make sure that spring (7a) will not slip away from oil seal lip even when
intermediate rod has been deadly scratched. Apply light duty lubricant on intermediate
rod so that elements inside the stuffing box are easy to be fixed.

6. Spray Pump Assembly

The spray pump assembly consists of spray pump, water tank and spray pipe with nozzles etc.

The function of spray pump is to supply water in the form of spray to the cylinder liner and piston to

flush, lubricate and cool them to extend the service life of the cylinder liner and piston.

The spray pump is a centrifugal pump, which is electric motor driven through pinion shaft and uses

water as cooling and lubrication fluid. Attention must be paid to assure the cooling fluid is supplied to

the cylinder liner and piston, otherwise immediate damage of piston rubber parts and cylinder liner will

occur.

The LGF series mud-pumps manufactured by our company use a stationary spray pipe, as shown in

Figure 5, which consists of a fixture (1), connecting pipe (2) and spray nozzle pipe (3). It sprays the

cooling fluid to inner holes of cylinder liner and piston. The spray nozzle pipe should be checked often

as the pump works. Through adjustment of water supply to the manifold, to assure enough cooling fluid

to be sprayed directly to piston.

Fig. 5
Cooling fluid will be transfused by pump (item3, Figure 7), and sucked from water tank (item 5, Fig.7),

to the manifold located in the left (right) wall plate of the frame. By regulating the ball valve (item 4,

Fig.7), the pump will supply water to the inside of the cylinder liner without splashing back on the
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

crosshead extension rod. Water should not splash on the extension rod otherwise some of water will

spray into the power end contaminating the lube oil.

The cooling fluid is returned from frame drainage hole to water tank’s setting chamber, and as the

fluid flows through the filter screen, the solids settle as shown in Fig. 6.

It is important to check condition of the cooling fluid at frequent intervals and clean and flush the

water tank as well as replace the cooling fluid as required; otherwise the contaminated fluid will cause

early wear of liner and piston or block the spray nozzle pipe.

frame drain

filter
screen setting
chamber drain

to spray pump
suction pipe

Fig. 6

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OPERATION MANUAL FOR LGF-500 Drilling Pump

5
4
3
2
1

Fig. 7

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

7. Assembly of Fluid End Parts

The cross-section of the fluid end is shown in Figure 8, clean and install all parts of the fluid end must

follow the methods as follows.

Note: The parts in the fluid end are designed for ‘metal to metal’ installations to reduce
wear caused by high-pressure fluid which is used in modern high-pressure-pump operations.
Based on this consideration, in order to ensure a reliable sealing between parts in the fluid end,
it is required to clean all parts thoroughly and have no burrs, scores or rusty spots etc.

7.1 Valves and Seats

Remove all three valves pot cover (18), three cylinder heads (16) and plugs (15), and thoroughly

clean all machined surfaces in the fluid end with a good cleaning solvent.

Make sure all valve seat bores are very clean and dry (free of dirt, grease, anti-rust additives etc.),

and remove all burrs and nicks with a fine emery cloth. Clean and dry thoroughly the valve seats and

install suction and discharge valve seats into the valve cavity bores and then install the valve body;

knock the upper part of the guidepost with a copper hammer to drive the valve seats in place, finally

install valve springs and other parts.

7.2 Cylinder Liner

Check the cleaned cylinder liner hole to make sure that there are no foreign matters inside. Apply

grease or lubricant to lightly coat the surface of liner hole and push the liner into the hole until both the

shoulders on liner and the hole touch together to form metal to metal contact.

Prevent foreign matters from entering inside while fitting on; otherwise foreign matters inside may

cause the liner to tilt and result in quick wear-out of liner and piston.

7.3 Piston Rod

Clean piston rod (24) and piston (22); make sure they are free of burrs and nicks. Install piston seal ring

(23) in groove of piston core and slide piston (22) on the rod (24) and ensure that the O-ring is not

dislocated out of the groove. Tighten piston rod nut (21) to a torque: 368ft.Ibs（500N.m）.

Coat internal surface of liner and external surface of piston with grease; check the ends of piston rod

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

(24) and intermediate rod to make sure that the surface is clean and free of burs and nicks. Insert

piston rod (24) into the liner (25) to be centered at the liner rear part. Drive the piston into the liner (25)

with a piece of hardwood or special tool. Make sure not to damage the positioning dowel of piston rod

(24) end when approaching the intermediate rod of crosshead. The piston rod (24) must be supported

and guided into the positioning bore of intermediate-rod.

7.4 Piston Rod Clamps

The piston rod clamps (27) are machined as one piece and then cut into two halves; and the two

pieces are stenciled with matching numbers and linked together with a chain. They must be used in

pairs with the same matching numbers. Before installation of the clamps (27), the splash- guard (R7)

must be installed on the end of intermediate rod and the clamps (27) clip on the end flange chamfer of

the piston rod (24) and intermediate rod. Tighten bolts to the torque of 100 ft.lbs（135N.m）.

When the piston rods (24) and clamps (27) are new, there is a gap of about 1/4″（6.4mm）between

the two halves of the clamp to ensure that the end faces of piston rods form a good ‘metal-to–metal’

connection. As wear occurs, the two halves will be pulled closer; if no gap exists, the clamping force will

be lost and the clamps need to be replaced. Finally, install the liner end cover on rear part of the

cylinder liner.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

24 23 22 21 20 19 18 17 16 15 14 13 12 11
10 R3 R4 44
25
8 9
26 7
6
27
5
R7 4

28 3
44 R5 R6 44
R2
2
R1
1
42 29
30 20A
31
32
33
35 36 37 38 39

Fig. 8

7.5 Lower Valve Stem Guide and Cylinder Pusher

Install seal ring (4) onto the rear part of liner and fit in the liner as fig.8. Fix the cylinder pusher (6)

into cylinder port to align the lower hole on cylinder pusher with the hole of valve cavity below. Install

the guide (30) through the lower hole of cylinder jacket on the stem of lower valve body and rotate

the guide. Press down the guide and fit the spring into guide till the guide may be rotated 1/4 circle

and be seated into the lower part of cylinder pusher. The guide clamp (29) is to be fit into slot on the

lower stem guide. Rotate the clamp rightwards to clip the valve stem guide into the cylinder pusher

so that the guide is locked. Sometimes it is necessary to bend middle section of the calmp more or

less to clip its petiole in the right location in order to tightly clamp the guide.

7.6 Cylinder Head

Fit the seal ring (4) against cylinder pusher into cylinder port and install on cylinder head plug (5).

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Apply lubricant to cover fit-in thread of cylinder head (3). Spin in cylinder head (3) against the plug (5)

and tighten the cylinder head with extention wrench rod and hammer.

In case of fluid leaking out from drain hole, it indicates that the seal has been damaged or cylinder

head has become loose. Don’t block the drain hole; otherwise the failure of cylinder head seal may

cause thread on cylinder head and its flange to be damaged

7.7 Valve pot cover

Fit the seal ring (12) of valve bonnet into hole. Apply lubricant to coat the seal and thread location

of valve bonnet and tighten the valve bonnet with extention wrench rod and hammer.

7.8 Discharge Manifold

4″ (102mm) 5000psi flange is used for discharge manifold. Having removed the flange and the ring

gasket, weld the flange to the discharge line (types of welding will be selected by user). Tighten the

flange connection bolts and nuts alternately to the torque: 950～1000ft.lbs（1287～1355N.m）. If the

other end of the manifold will not be pipeline-connected, a blind flange can be installed and tighten the

bolts and nuts as the way mentioned above.

7.9 Suction Flange

The suction flange is an 8” (203mm) bore flange, which is custom-made and connected and matched

with the inlet flange of the suction line. O-rings seal the flange connection. Before connecting, clean the

O-ring grooves and flange end faces and then tighten the bolts to the torque: 140～160ft.lbs（190～

217N.m）

7.10 Accessory Manifold

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

2
NPT3
NPT2
I
6 7
4 5

Fig.9

The accessory manifold is shown in the figure 9. It may be installed on the discharge manifold and

opposite to the discharge filter screen assembly. This accessory manifold is connected with KB-45

pulsation dampener (1) through the discharge bend- tube assembly. On one sides it is a NPT3 outlet

and a NPT2 outlet on the other side, connected respectively with reset relief valve (3) and pressure

gauge (2).

Note: A reducing bushing will be used when the pressure gauge interface threads are R2 1 1/2.

The accessory and discharge manifolds are connected by flanges; before installation, clean

thoroughly the flange seal ring grooves and then insert the ring gaskets (4), and tighten the

connection nuts (5) to the torque: 950～1000ft.lbs（1287～1355N.m）. To ensure a uniform force

is exerted on the seal gaskets connections, tightening the nuts should be done

cross-alternately.

The reset relief valve (3) is installed on the accessory manifold for the purpose of protecting the pump

from pressure exceeding the rated value and discharging all the fluids to guarantee safety of the mud

pump. The reset relief valve must be installed in such a way as directly contacting to mud fluid; and no

valves are to be installed between the relief valve and the discharge line. Pipe the outlet of the relief

valve directly to the mud tank by seamless steel pipe with as few turns in this line as possible. If a turn

is necessary, the elbow bend should be > 120°. It is not allowed to pipe the outlet of the relief valve to

the suction pipe of the pump.

Work pressure rate is marked on the reset relief valve body. To regulate pressure it is merely to insert

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

the shear pin into the relevant hole. It is to be noted that only one shear pin is needed inside the hole of

shear plate. If the cylinder piston size changes, the relief valve pressure has to be adjusted. Be sure not

to use inner hexagonal spanner, welding rod or other material to take the place of safety pin; otherwise

it will affect adversely the pressure value of relief valve and result in personnel injury.

The flange on the bottom of the KB-45 pulsation dampener (1) is supplied together with R39 ring

gasket (6); before installation of pulsation dampener , clean the ring gasket and groove thoroughly and

after installation, tighten the nuts (7) to the torque: 950 ～ 1000ft.lbs （ 1287 ～ 1355N.m. To ensure

balanced forces to be exerted, all nuts should be tightened alternately crossways.

Before starting the pump, pre-charge the pulsation dampener not to be more than 2/3 of the pump

discharge pressure. Maximum pressure is not to exceed 650 psi (4.5 Mpa). The pulsation dampener

shall be charged with nitrogen or air. It is not allowed to charge with oxygen, hydrogen or other

easy-burning and explosion gases.

The charging will be conducted with a set of charging equipment (pulsation dampener charging hoses

assembly) provided together with the pump, as shown in Figure 10 and the operation sequences are as

follows:
氮气瓶开关

1 2 3 4 5 空气包截止阀

Fig. 10

（1）Nut （2）Seal Joint （3）Connector （4）Combined seal shim

（5）Threaded Plug （6）Hose

1. Remove dampener pressure gauge cover, rotate vent valve handle about 1/4 –1/2 of a circle

to release the remaining pressure and make the pressure gauge reading as zero; remove vent

valve capping and plug.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

2. Connect the nitrogen cylinder valve to the dampener vent valve by a hose

3. Open the shut-off valve of the dampener

4. Open the nitrogen cylinder valve slowly and adjust the airflow into the dampener

5. Close the nitrogen cylinder valve when the reading of dampener pressure gauge is up to the

pressure required

6. Close the dampener shut-off valve

7. Remove hose and install the cover on pressure gauge. Reinstall the vent valve cap and plug.

To achieve the best results, the dampener pre-charging pressure must not be more than 2/3 of the

pump discharge pressure, and the maximum charging pressure is 650 psi (4.5 Mpa).

Warnings:
a. The pulsation dampener must be charged only with compressed nitrogen or air. It
is not allowed to charge with oxygen, hydrogen or other easy-burning and
explosive gases.
b. For maintenance of the dampener, the pressure in the dampener must be zero and
the pump pressure also is zero. Don’t fully rely on the pressure gauge readings.
The vent valve cap must be opened to release pressure as the remaining pressure
may be low and the pressure gauge may not read correctly. This low pressure may
also cause an accident.

8. Lubrication
It is very important to lubricate properly all moving parts, which directly affects the service life of the

parts. To obtain the longest service life without failures for all parts of the power end, regular

maintenances and inspections must be done to ensure proper and clean lubrication oils flow to all

moving parts.

8.1 Minimum Operating Speed

To lubricate whole power end, a combination lubrication system of oil bath splash and pressure

systems is adopted for LGF series pumps. When a gear oil pump is driven mechanically (except driven

by an electric motor), the types of pressure lubrication system adopted, in fact, govern the minimum

SPM, at which the pump being operated. As for the pressure lubrication systems adopted for LGF

series pumps, they could operate at a minimum 25 SPM; at this time, the lowest oil pressure is 5 psi

(0.035 Mpa).
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Big gear rim

Pinion shaft

Oil pump gear

Fig. 11

Note: The pressure lube oil pump could be installed outside of mud- pump and driven by v-belt

or installed inside of mud- pump and driven by big gear rim. When the later installation is used,

the rotating direction of the pinion shaft should be as shown in figure 11.

8.2 Flow- controlled Splash Lubrication System

The flow- controlled splash lubrication systems are the same for all LGF series pumps, regardless of

the types of oil pump provided for the lubrication system. In the flow-controlled splash system, the big

gear rim brings up the oil from the sump; and when its teeth mesh with the pinion, the oil is squeezed

out and splashed to various oil troughs and oil cavities in the frame. With reference to figure 13, the oil

is thrown into the trough (7) and flow through pipe (8), to the bearings on the two sides of the pinion

shaft.

The passage that oil flows from the top of the crosshead guide into the crosshead bearings is shown in

Fig.12. The oil accumulating in chamber above the crossheads will flow through oil passage (1), (2)

and passage (3) inside the pin on crosshead into the bearing of crosshead pin. There are two oil

passages (3) to rotate the pin on crosshead with no care about the alignment. This permits the

installation of crosshead being possible from either direction of the frame’s two sides.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Fig. 12

8.3 Pressure Lubrication System

The pressure lubrication systems used for LGF series mud- pumps have been installed with a lube oil

pump, as shown in Figure 13. In this system, the filtered oil is sucked in, through the suction filter (1), by

the lube pump, and then the lube pump, through the block II (2), distributes oil to the pinion shaft nozzle

(3A), main bearing oil-pipe (4) and the block I (4A) in crosshead chamber and again, through the block I

(4A), distributes oil to the crosshead, its bearing and intermediate rod.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Fig. 13
A pressure gauge (5) is mounted on the back base plate of the frame to show oil pressure in the

block oil-distributor, which obviously changes with the speed of the pump. However, if a sudden

pressure drop or increase occurs, the possible reasons are to be found out referring to the section on

“Maintenance of Lubrication System”.

A pressure relief valve (6) is mounted on the block II (2) to prevent damage to the pump and its

drive caused by excessive pressure. The relief valve is preset to 80 psi (0.55 Mpa) and then locked

down to avoid the preset pressure change.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

3 2 1

Fig. 14

Upon built-in installation of the lube oil pump, as item 10 shown in Fig.13, the pump must be well

positioned according to the requirements as shown in the drawing. The side face of the oil pump gear

must be flush and parallel with the side edge of the mud pump main gear rim, and the gear teeth have

0.024”-0.0355” (0.60-0.90 mm) clearance.

A typical layout for oil pump driven by pinion shaft is shown in Fig.14. The oil pump (1) is

pipe-connected to the lube oil pipes system through the suction and discharge adapters mounted on

the lower part of walls of the power end. Don’t over-tighten the V-belt (2) to prevent the pump from

premature damage. To avoid possible injury, the V-belt guard, as item 3 shown in Fig.14, must be

installed before the pump being operated.

8.4 Maintenance of Lubrication System

Sufficient lubrication of all moving parts is the most important factor to extend the service life of the

pump; being meticulous in maintenance of the lube oil system is a duty for all operators. In fact, a good

or poor maintenance of the lube oil system determines a long or short trouble-free service life of the

pump.

The recommended lubrication oil is as follows; and also shown on nameplate fixed on the pump

side. All data recommended are the results of long-period tests in the oil field; therefore, any

substitution of oil recommended could only be used for emergency conditions.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Lubrication specification:
Use of extreme pressure (EP), non-corrosive and anti-foaming gear lubrication oil is specified as

follows:

Ambient temperature: +30°F～+ 155°F （-1°C～+ 68°C）

AGMA 250.04EP（6EP）or ISO VG320

Ambient temperature: 0°F～+ 80°F （-18°C～+ 27°C）

AGMA 250.04EP（5EP）or ISO VG220

Ambient temperature: -20°F～+ 40°F （-29°C～+ 4°C）

AGMA 250.04EP（4EP）or ISO VG150

Oil reservoir capacity: LGF-500 65 US gal（246L）

Every shift should make their rounds to check the oil level and maintain the level at the FULL position;

in view of oil level compensation, it is allowed to drive the pump for 5 minutes at a slow speed and

make sure the oil level at the specified position.

Check once every 6-month if the oil has any sand and corrosive compounds in it or not; it should be

drained. Drain all the oil and flush the oil reservoir before adding new oil. The oil drains are located on

either side of the pump frame. During flushing, thoroughly clean the oil troughs and the chambers

under the crosshead guides, and also clean or replace the filter element in the suction oil filter, and

clean the suction filter screens. Before filling new oil remove the drain cover from setting chamber and

clean out contaminants.

Regularly check the condition of the lube oil and replace the oil as air moisture, water, dust and mud

fluid may intrude.

The settling chamber (deposit chamber) is located in frame section near power end; the contamination

in the oil splashed into this area is allowed to settle and to be drained out by removing the threaded

drain plug located on the two sides of the frame.

Check once every month. Remove the drain plugs on two sides to drain out the contaminated oil from

the settling chamber. This will lose about 15 US gallons of oil and must be compensated by adding the

same amount of oil to the main reservoir.

Check once every week. Remove the 2 1/2” plugs in the lower part of pump frame and drain out the

accumulated water. Every shift makes their round of inspection of oil level once and keeps the level to

the full position.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

In case of oil pressure drop occurs; check the following items:

--- Suction filter screen may be blocked

--- Oil level may be too low

--- V-belt slips

--- Connections or joints may be broken or loose

--- Oil pump may be worn or damaged

--- Relief valve fails

In case of oil pressure increase occurs, check the following items:

--- Oil passage may be blocked

--- Contaminations may make the oil to be sticky

--- Relief valve fails

--- Pressure gauge fault

--- Other abnormal conditions

9. Maintenance
9.1 Power End
Regular inspection of the power end is the most important way to conduct preventive maintenance; it

can timely find out various small or big failures, and enable the mud pump to be repaired according to

plan or in the normal shutdown time.

a. Check tightness of the main bearing bolts to the torque: 3000ft.ibs (4065 N.M)

b. Lock wire tightly

Check all bolts including main bearing cover bolts, and check all locking wires on the bolt head of all

crankshaft-bearing baffles; after retightening bolts, the locking wires must be replaced. Refer to

crankshaft assembly section for bolt torques required.

c. Oil pipe-line

Check all oil pipelines and make sure that they have not been damaged and free of obstructions.

Check the pump suction pipelines are free of damage and being staved.

d. Suction filter

Check suction filter status, clean or replace it if necessary.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

e. Main bearing cover

Remove the main bearing cover; check tightness of main bearing bolts and condition of the bearing

rollers. Clean and remove any sludge, dirt or foreign objects, as they might be accumulated in the

bottom of the bearing area.

f. Teeth of main and pinion gear

Check the condition of the main and pinion gear teeth for any abnormal wear. During the running-in

period there will be some pitting on the face of the gear teeth. This is referred to as “initial pitting”

and is not harmful to the life of the gears; however, during the regular check if the pitting is

expanding, immediately contact the pump manufacturer to inspect the gears thoroughly.

g. Crosshead pin bolts and crosshead guide

Remove cover and check condition of the crosshead pin bolts and locking wires. (The back cover

can be removed and the intermediate rod may be rotated to outer dead point while checking the

middle crosshead pin). Tighten the crosshead pin bolts (item 4 in Fig. 18) to the torque: 90 ～

100ft.lbs（120～135N.m）

It is necessary to use a torque wrench and not to exceed the above-mentioned torque value.

If the crosshead or guide shows abnormal wear, replace it immediately as it may cause damage to

the bearings and other parts and speed up the wear to the piston and cylinder liner by the excess

wear.

h. Lube oil and oil reservoir

Check condition of oil and cleanness of the oil reservoir; service the oil lubrication system as

specified in the section on Lubrication of this manual.

9.2 Roller Bearing

Roller bearings are used for all LGF series mud- pumps. As very precise mechanical parts, all roller

bearings must be carefully maintained to ensure that higher load capacity and longer service life to be

obtained.

Spherical self-alignment roller bearings are used for crankshaft main bearings. The pinion shaft is

mounted on short-column roller bearings. The eccentric bearings are single-row short-column with

detent ring roller type to be easily removed. The crosshead pin bearings are double-row long-column

roller type. None of the bearings require special adjustments.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

All inner and outer rings are assembled and fitted very accurately as the fit clearance of bearings are

very small; therefore, they must be used in sets. If one element of a bearing fails (inner or outer rings,

rollers or retainer), all elements must be replaced as one set. If excessive clearance, groove or wear in

socket ring and spot corrosion or scaling on parts occur, it indicates that these bearings have already

failed and must be replaced as soon as possible.

All roller bearings are assembled to shafts by shrink fit (refer to every bearing assembly for the bearing

fit data). Damaged or worn bearing or socket ring can be removed by driving them off the shaft with a

copper rod and hammer or by gas cutting with special attention not to damage the shaft. Bearings

assembling usually use the way of heating in an oil bath; but the temperature should be below 300℉

（149℃）. Make sure that both the oil and tank must be very clean; if the oil were directly heated by

open fire under the oil tank, the bearing inner ring must be supported while putting it in the oil tank and

don’t leave the bearings in the tank longer than 3 minutes.

Don’t heat the bearings with a torch unless it is the only possible means available. When heating by

torch, it must be only operated by an experienced gas-welder; the torch and the bearing must be at

least 6” (150mm) apart. Use a tempilstick to measure the temperature. Don’t overheat the bearings;

otherwise, the bearing will soften owing to tempering of metal.

Once the heated bearing is in place on the shaft, it should be naturally cooled, never use water or other

liquid to cool the hot bearing. Rapid cooling will cause the bearing’s inner and outer rings as well as

rollers to be ‘thermal-cracked’ and damaged.

Never strike bearing with a steel hammer, upon installation a wood hammer might be used to drive

lightly the bearing in place.

Usually coat the shaft neck and fixing bores by grease before installation of bearing; the best one for

this purpose is called as ‘white lead oil’, i.e. a kind of anti-sticky compound oil.

Before installation, open the packaging box and take out the bearings; be sure that prevent any dirt and

other foreign objects enter into the bearings; and remove packaging antirust grease and clean all

bearings thoroughly with kerosene or other solvents.

9.3 Pinion Shaft Assembly

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

11 16 15 C B B C 14 13 12 11 17 19 18

Fluid end

1 2 3 4 5 A A 10 9 8 6 7

Fig. 15
The fittings between parts on the pinion shaft assembly and bearings are shown in table Ⅳ.
Table Ⅳ
Matching location Marked by Numerical value
Bearing inner ring to shaft T0.0012″～T0.0032″
A
neck （T0.030mm～T0.081mm）

L0.0005″～L0.0027″
Bearing outer ring to bore B
（L0.013mm～L0.068mm）

L0.003″～L0.008″
Bearing carrier to frame bore C
（L0.076mm～L0.203mm）

In this table, T indicates interference and L indicates clearance.

The gear and shaft are machined as an integrated unit; belt sheave or chain sprocket may be

installed on either side of the shaft. Fit clerances of the bearings are determined by their precision of

fitting with the shaft and the inner hole of bearing sleeve. When performing maintenance or overhaul,

make sure the requirements in Table Ⅳ are obtained. Having installed the inner ring and seal sleeve

(15° bevel edge towards outside) of bearing by shrink fit on the pinion shaft neck, the installation of

pinion shaft assembly is completed, and then the pinion shaft assembly can be installed in frame bores

at either end into the frame assembly (see Fig. 15).

When installing the pinion components in the frame assembly, the following points should be noted:

a) Ensure the seal washers (6) of bearing carrier and the end cover seal washers (5) are

correctly in place.

b) When installing the bearing carrier (7) and end cover (4), make sure the oil groove is

positioned downwards and aligned with the drain hole; moreover, the oil-accumulating box on
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

the bearing carrier should also be installed downwards.

c) Remove burrs, dents and gouges from outside surface of the seal sleeve (3), and then

install end cover (4) in place. Take care when sliding the seal lip over the keyway on the end

of shaft as the lip may be damaged by the sharp edge of the keyway; when sliding seal into

the seal sleeve the seal lip is not allowed to be turned over the carrier edge.

d) Tighten bearing carrier bolts (12) to the torque: 100～125ft.lbs (135～170 N.m)

e) Check condition of the pinion bearing inner and outer rings and roller, if there is any wear,

galling, scaling and grooving or radial clearance exceeding 0.012” (0.30mm), it is

recommended a new one to be used to replace the damaged bearing.

9.4 Crankshaft Assembly

1 Assembly of big gear rim
Clean the aligning and fitting faces of the big gear rim and outside of the crankshaft hub

and heat the big gear rim to the temperature 176°F～248°F（80°C～120°C） and keep thermal

insulation for one hour, and then mount on the crankshaft by shrink fit. When the temperature

dropped down to room temperature, tighten the nuts (19) and bolts (11) crosswise to the torque:

295 ft.lbs（400N. m）. Check the diameter and end plane run-out of the big gear rim after installation

by the ways as follows: first mount the crankshaft into the frame assembly, and then rotate the big

gear rim and measure its diameter run-out on gear rim circle directly by a dial indicator. While

measuring the gear rim end plane run-out since it also affects the running clearance the of main

bearings, it must be measured simultaneously at the shaft end and gear end face by two dial

indicators; therefore, the actual run-out at any point is a difference of the two readings.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

G H
液
力
1 2 3 4 5 6 7 8 9 端 10 E 11 12 13 14

C D
F
F

27
25
20

B 15
A

18
25
27
C D
24 21 23 C D 22 25 27 28 19 20 25 27 17 16 26

Fig. 16
2 Install the inner ring of the eccentric bearing on the crankshaft eccentric shaft neck by shrink fit and
mark the matching bearing pair well; first install the bearing in middle and then at both sides, while

installing the inner ring of the right eccentric bearing, the locating ring (7) should be first installed.

Tighten the allen screws (28) to the torque: 18～26ft.lbs（ 24～36N.m）and lock them with steel wires.

3 Heat the link big end to the teperature 176°F～248°F（80°C～120°C）and install outer ring of the
eccentric bearing, and mark the the matching bearing pair well; When the temperature dropped down

to room temperature, install the outer detent ring (5) and keep its scoop positioned at the bottom and

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

tighten the bolts (20) uniformly to the torque: 44～66ft.lbs（ 60～90N.m）and lock them with steel wire.

4 Heat the link small end to the temperature 176°F～248°F（80°C～120°C）, install the outer ring of
the crosshead bearing into the link small end bore according to the matching marks.

5 Install the link on the inner ring of the eccentric bearings and install the inner detent ring (4); tighten
bolts (20) uniformly to the torque: 44～66 ft .lbs（60～90 N. m）and lock them with steel wire.

6 Install first main bearings on the bearing carrier by shrink fit and then together be installed on the
crankshaft also by shrink fit; when the temperature dropped down to room temperature, install detent

ring (14) and baffle plate (15). Tighten uniformly the bolts (20) to the torque: 18～26ft.lbs（ 24～36N.m）

and lock them with steel wire. Before shrink- fitting, the bearing remember to install the spacers (12).

It is noted that the left main bearing sleeve (13) difers with the right main bearing sleeve (2) in shape

and dimension.When installing, the round shoulder on left main bearing sleeve is used to locate and

fasten crankshaft assembly in position on frame. The left and right main bearing sleeves are

interchangeable in fit-on position.

9.5 Installing Crankshaft Assembly in Frame Assembly

In order to obtain a more precise fit between the main bearing sleeve (right and left) and the frame bore;

the following steps should be followed.

1. Before lifting crankshaft assembly, put a piece of woodblock between the link small end and

crosshead guide (see Fig. 19), to prevent the guide from possible gouging as sliding the link in

place.

2. Rotate the main bearing carrier so that its two symmetry planes are parallel with the main bearing

bolt holes and provide clearance for the main bearing bolts to ensure the main bearing bolts to

pass in; and slowly lower the crankshaft into position.

3. After installing the crankshaft in the frame and before installing the main bearing caps, check the

bearing rollers of each row at each side are equally loaded. Tighten the main bearing bolts only

when the numbers of inner and outer rollers supporting the dead weight of the crankshaft are equal.

Owing to the affects of manufacturing tolerances etc, the total number of the rollers may vary

slightly.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Bearing bolt Main bearing

Lead wire Bearing sleeve

(～0.60mm)

Bearing cap
crankshaf

tt

shims
(0.50mm)

Fig.17
4. Install and shim main bearing cap; and make the main bearing carrier have a interference of

0.0024″～0.004″（0.06mm～0.10mm）to obtain a preset tension through adjusting the thickness of

the shims. There are two ways to decide the thickness of shims (as shown in Fig. 17):

1) Put steel shims with thickness of 0.0394″（1mm） in main bearing cap matching face

2) Add a length of lead or plastic wire of 0.0787″（2mm）in the middle of matching area between

main bearing cap inner hole and bearing sleeve.

3) Tighten all main bearing bolts as per prescribed torque of 3000ft.Ibs（4065N.m）.

4) Remove the main bearing cap and measuring the thickness of the lead wire.

5) Precompression of the main bearing cap is 0.0024″～0.0039″（0.06mm～0.10mm）

6) Actual shim-thickness needed = shims thickness 0.0394″ （ 1mm） – compressed lead wire

thickness – bearing precompression 0.0024″～0.0039″（0.06mm～ 0.10mm）.

Note: Different matching tolerances for right and left sides make it necessary to measure and

determine the shim-thickness for both sides separately. And then place the shims under the

main bearing cap according to the thickness above-determined respectively; tighten all main

bearing bolts to presribed torque. Recheck the load condition of inner and outer two-row roller

at both ends as mentioned above to ensure that each bearing has the same load.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

9.6 Installation of Crosshead Guide Sleeve

When crosshead guide sleeve is heavily worn out or damaged, it must be replaced with a new one.

(Note: First disassemble crankshaft prior to removing crosshead guide sleeve). Following procedures

are to be used to replace the guide sleeve: (referring to Fig.18)

Fig. 18
1. Remove the worn or damaged guide sleeve.

2. Completely clean frame holes and contact end face (locationA) to make sure no dusts or other

foreign objects remain on above mentioned surfaces so as to ensure that the centerline of guide

sleeve is in the same line with that of both power and fluid ends.

3. Fix “O” ring(1) into front part of the guide sleeve, coat the sleeve surface with lubricant and fit

the guide sleeve into frame hole. The outer surface of guide sleeve is to be fitted with frame hole

(location B) as follows:

L0.004″～L0.008″ （L0.102mm～0.203mm）

L——clearance

4. Install and tighten bolts (2) with torque below, and place the guide

600～800ft.lbs （813～1085N.m）

Tighten the bolts crossways to ensure the uniform spin up torque apllied.

5. Use 0.001″～0.002″（0.025mm～0.050mm）feeler gauge to check the engaging face A to ensure

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

a tight engagement.

6）Install input oil tube(3) and(4).

Note：When the guide sleeve is damaged and it is impossible to replace with a new one as
time is pressing, the damaged bottom surface may be turened 180° afte removing crankshaft
assembly so as to let crosshead to move on the new guide sleeve surface; whereas the
damaged guide sleeve may be replaced in a proper time later

Fig. 19

9.7 Installation of Crosshead

The crosshead can be installed from the front end (fluid end) or guide back end (power end), refer to

Fig. 19 and follow the following steps:

1. Thoroughly clean all dirt or contaminations and remove all burrs or rough edges from OD, pinhole

of the crosshead and guide inner bore etc. Wipe and dry crosshead pinhole so that the connection with

the pin taper bore is made up as ‘metal to metal’ one. See following note.

2. Position the small end of the link at the side hole of the crosshead guides. Support the link with a

piece of wood so that the crosshead pin can pass through the bore of link small end while sliding the

crosshead into the pinhole at the aligned positions. See Fig. 19.

3. Install the left side crosshead first and then rotate the crankshaft assembly to make the middle link

hole into the middle crosshead; at this time the right link hole backs, remove the splash guard disk (see

item1, Figure 19); push the right crosshead to the middle extension rod chamber so that enough

clearances are provided for installation of middle crosshead, and then install the right crosshead.
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Note: If an old guide is to be reused, check the wearing surface for wear and scoring etc.
The crosshead might be installed to opposite side of the pump if necessary i.e. the left and right
crosshead could be exchanged - installed into the bores, and rotate the crosshead 180° to place
cross head’s smooth surface below. In this case, cross head pin shall be fixed into hole from
opposite direction against the previous one. However, don’t install the pin into the taper hole
until the crosshead pin baffle (2) is mounted.
4. Install crosshead pin baffle (2) and bolts (3). Align the taper hole of crosshead with the link small

end hole, and push the pin by hand or knock the big end of the pin lightly by a hammer to install the pin

into the taper bore. Put the adjusting shims between crosshead pins and baffle (note: as to a set of pin

and its hole, the thickness of shims needed are determined and not exchangeable with other shims,

otherwise, failures may occur); rotate crosshead pin until the 4 bolt- holes (4) align with the holes below,

and install and tighten 4 bolts by hand equably (refer to Fig. 20) with torque 0～100ft.lbs (120 ～ 135

N.m). The bolts are to be locked by wires.

Fig. 20
Use torque wrench and don’t exceed the torque specified above.

Note 1 ： Over- tightening the bolts (4) of crosshead pin baffle will cause outside convex of
crosshead outer to decrease movement clearance in the middle of crosshead; at this time, the bolts (4)

of the crosshead pin baffle must be loosened and retightened according to the requirements in item 4

above-mentioned.

Note 2：Steps for pulling out the crosshead pin: Remove 4 bolts (4) on baffle plate and rotate two
of them into the “jack screw” holes (5); tighten the two bolts until the pins become loose. Remove

crosshead baffle (2), and then take out the pins from the holes.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

9.8 Check Crosshead Alignment

In order to let the piston move correctly in the liner, the crosshead must travel horizontally along the

centerline of the frame hole. To check and align the crosshead as follows:

1. Remove the baffle plate.

2. Position the crosshead at the extreme front of its stroke. Carefully measure the distance from the

extension rod to the splashguard disk hole at the top and bottom with inside calipers or telescoping

gauges; compare these two measurements to determine the position of the extension rod relative to the

centerline of the bore.

3. Rotate pump to extreme rear of stroke and take measurements again at the same place; compare

these measurements with those taken at the front of the stroke to determine if the crosshead is running

horizontally.

4. If concentricness of the extension rod (ie. The consistency between piston rod axes and the

longitudinal axes of frame hole) exceeds 0.015” (0.381mm), the guide sleeve and crosshead may be

turned 180° for reuse or be replaced ( in this case, crankshaft assembly must be removed).

9.9 Maintenance of Fluid End

With the increase of pressure used for drilling equipment, the damage to the fluid end often occurs.

However, good maintenances for all parts and components of the fluid end will make them have a

longer and more proper service life.

The points requiring attention are as follows:
1. Before starting the pump, make sure all valves installed on the high-pressure discharge manifold

must be open. While the valve are closed, the pump starting will exert an impact stress to the pump

(cylinder body) and may cause fatigue cracks; and finally the pump head would be damaged by fatigue

failure if the situation continued.

2. Don’t engage the clutch when the prime mover (diesel engine, electrical motor and transmission

unit) is running at a high speed; otherwise, it will cause some additional and undesirable shock

loads against both power and fluid ends.

3. Properly maintain high-pressure relief valves and reset pressure according to the cylinder liner

installed to ensure that the relief valve may be opened to relieve pressure at working pressure is

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

being exceeded.

4. Don’t operate the pump for a long time if a severe fluid knock is present.

Properly maintain the fluid ends for storage. When a pump will not be used for 10 days more, it is

suggested to remove the pistons. piston rods, liner etc and flush thoroughly the fluid end with clean

water and then wiping them clean after flushing; grease all parts removed and all machined surfaces.

This will not only extend the life of the fluid end parts but also protects them in good condition to be

installed when the pump will be operated again.

The fluid end assembly for triplex pumps consists of 3 forged fluid cylinder blocks, liner, valve bonnet

and cylinder head, suction and discharge manifold etc.

a. Cylinder block

The structure of the cylinder block is shown in Figure 21 with dimensions in Table Ⅵ.

The 3 independent blocks (1) are connected to the frame of power end through stud-bolts (2); and

guided by wear plate outer boss (shoulder or flange) on the cylinder block and aligned by fitting with the

power end frame bores. Upon installation, all burrs, dirt and dents etc should be removed from

wear-resistance disk outer boss on the cylinder block and all frame inner holes’ mating faces, otherwise

there will be warping

Table Ⅵ
Dimension
Location
in mm
A 8.505～8.510 216.03～216.15
B 7.505～7.508 190.63～190.70
C 12-1/2 317.5
D 6.125～6.130 155.58～155.70
E 5.375～5.380 136.53～136.65
F 4.995～5.000 126.87～127.00
G 5-5/16 135
H 9-1/8 231.8
J 8 203.2
K 2-1/2 63.5
L 3 76.2

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Fig. 21
b. Suction manifold

The suction manifold (3) is connected with each cylinder blocks by bolts and sealed by O-ring (4) in

the connection faces with flange. Before installation, thoroughly clean O-ring grooves and sealing

surfaces in the cylinder block, and then insert O-ring; to ensure good sealing, the flange connection

must be made up ‘metal to metal’ to retain the O-ring seal, therefore, any nicks, grooves or galling on

the sealing surface must be repaired. Refer to the following section 9.10: Welding and Repair, of this

Manual for detailed repairing steps.

Before tightening the bolts (5) of suction manifold, the bolts (2) on the three cylinder blocks must be

spinned up but not tightened, finally tighten them to torques indicated in Table Ⅶ with torque wrench

(see description below).

c. Discharge manifold

The discharge manifold (8) is fixed on each cylinder block with stud bolts and nuts and sealed by O-

rings. Before installation, thoroughly clean O-ring grooves in the cylinder block and sealing surfaces on

the discharge manifold; and the connection must be made up ‘metal to metal’ to retain the O-ring seal,
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

therefore, any nicks, grooves or galling on the sealing surface must be repaired. Refer to the following

section 9.10: Welding and Repair, of this Manual for details.

Before tightening the nuts of discharge manifold, the bolts (2) on the three cylinder blocks must be

spinned up but not tightened, finally tighten the fastening nuts between cylinder blocks and frame to

torques indicated in Table Ⅶ with torque wrench.

d. Cylinder head flange

There are threads in cylinder head flange bore to facilitate removing of cylinder head (head); the

flange should be replaced if damaged. Before installation, thoroughly clean all burs, cutting edges or

foreign objects on the mating faces and install the flange “leakage groove” downwards. To ensure its

end-face is perpendicular to the axial-line of the cylinder block, a ‘metal to metal’ engagement on the

matching faces between cylinder head flange and cylinder must be made up. All nuts (10) must be

tightened to the torque as shown in Table Ⅶ:

Table Ⅶ
Position Item no. in Fig. Torque ft.lbs Torque N.m
With frame
2 1600 2170

Suction manifold 5 150 200

Discharge manifold 8 710 960

Cylinder head flange 10 710 960

9.10 Welding and Repairs

When repairing bores, for normal wear or being badly washed in the fluid end, the following welding

procedures must be strictly followed and all dimensions of the bores patched up be machined to size

specified in the drawing. In all cases, the bores’ shoulders (for installing cylinder liner, cylinder head etc.)

must be 90°to the axes line of the bores.

1、Welding procedures：
Distinction should be made between welding the prick damaged surface and cracks; the following are

some basic information for welding:

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

（1）、Prick damaged surface

 Welding as per the way used for 30 # carbon steel.

 Before welding, clean welding area by grinding or carbon-arc-air-gouging, be sure the

electrodes are dry and free of moisture, and if necessary, put them in an oven to dry before

welding.

 Spot-heat the welding area, at least for a surrounding 3” (75mm) area, to 250°F ～ 350°F

（120°C～180°C）.

Use low-hydrogen rod: AWS-ASTM E-60-7018, such as ADAM-Arc7018

 Temperature should be dropped down to 250°F～ 350°F（120°C～180°C）after finishing one

weld bead and then start welding the second. After all patches were completed, heat to

250°F～ 350°F（120°C～180°C）again and then start ‘thermal-insulation-cooling’.

（2）、Crack

 Grind out all cracks. It is not recommended to remove cracks by torch cutting since it will

cause the cracks to enlarge.

 Preheating: The purpose of preheating is to expand the area to be heated so that when

cooling, the welded area and the preheated area will cool more uniformly, thus to avoid

‘thermal cracking’ and prevent the ‘hard spots’ forming between the base metal and the

‘welding metal’; these hard spots are just the places the fatigue cracks will start

The welding procedures for cracks are the same as above-mentioned

9.11 Repair to Valve Bonnet Bore

When repairing the valve bonnet bore damaged by eroding, it is most important to keep the valve

seat end face to be completely levelled and 90°to the axis of the threads while turning or boring the

valve bonnet bores. As shown in the Fig. 22, the valve bonnet seal ring (1) seats into the counter-bore

at the top of valve bonnet and forms ‘metal to metal’ contacts; the seal ring was sealed in the lower

point machined by turning or boring, otherwise, a gap will be formed in between the end faces of valve

bonnet shoulder and valve bonnet bore, through which the seal ring will be extruded and damaged

under pressure. Any high or low spots could also cause the valve bonnet to become ‘warped’ and result

in severely damaging the threads.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

1 1

Fig. 22

10. Daily Maintenances of Pump

To maintain the pump properly is a necessary measure to ensure the pump is working correctly and

extend its service life. Importance should be attached to this key task during operation.

10.1 Daily Maintenances

1. Shut down the pump and check oil level at power end. Check once each day; if the pump is driven

by chain transmission, the oil level in chain reservoir should also be checked.

2. Observe working status of the cylinder liner and piston. If a little bit mud-leakage is found it is

normal; but if mud leaked is excessive, the piston needs to be replaced and the cylinder liner wear

should also be carefully checked. If excessive wear is found replace the liner.

3. Check the liner cavity of the frame and wash out the accumulated mud

4. Check the cooling water in the spray pump water tank. Replenish and replace the contaminated

cooling water if necessary

5. Check the charging pressure of discharge dampener up to the requirement specified.

6. Periodically test the reset safety valve.

7. Check the changes of lube pump pressure gauge. In case of low pressure (below 5psi or

0.035MPa) or no pressure, immediately check whether the suction and discharge strainers have been

obstructed.

8. Loosen the piston rod clamp everyday and rotate piston about 1/4 circle, and tighten the clamp

again. The purpose of this is to make the wear on the piston to be uniformly distributed around and

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

extend the service life of piston and cylinder liner.

9. Before tightening cylinder head and valve bonnet, first coat the threads with grease, and then

check the tightness of the bolts once within 4 hours.

10. Observe frequently the seals of valve bonnet, cylinder liner and leakage hole of cylinder liner seal,

replace the seal rings in time if mud-leakage is found and flows out.

10.2 Maintenances Every Week

1. Remove the valve bonnet, cylinder head once a week, clean them thoroughly, coat with

molybdenum disulfide-complex calcium grease, Check the inner sleeve of valve rod guide, if worn out

obviously ( the clearance between inner sleeve and valve rod guide ＞ 0.11” (3mm), replace

immediately.

2. Check the valves and valve seats and replace those worn. (Note: when replacing a valve seat, the

valve body should also be replaced.)

3. Check the piston locking nuts and replace if eroded or damaged. (After the nuts have been

tightened three times, the seal inside has already failed.)

4. Drain water from the clean out cover plugs until the oil comes out.

5. Check and clean the strainers in lube pump oil tubes one time.

10.3 Maintenances Every Month

1. Check all stud-bolts and nuts of fluid end, such as, cylinder head flange nuts, connecting nuts

between cylinder block and frame, bolts and nuts for suction and discharge manifolds etc. Retighten

them to the torque as specified if any loosening was found.

2. Check the seal rings in the extension rod diaphragm stuffing box, and replace those worn out. In

general, the seal rings should be replaced every three months and while replacing, pay attention to the

installing direction.

3. Remove and clean the filter element installed in the discharge filter.

4. Replace the contaminated oils in power end reservoir and crosshead settling chamber (deposit

chamber) every 6 months and at the same time, clean all oil grooves and lines.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

10.4 Maintenances Every Year

1. Check the tightness of the crosshead guide and running clearance up to the requirements or not, if

not it could be adjusted by adding shims under the guide. If the crankshaft assembly is removed for any

reason it is recommended to rotate the crossheads 180°for use again.(For purpose of easy handling,

exchange the crosshead position)

2. It is recommended to inspect the pump fully every two or three years. Check the wear and damage

status of main bearings, link bearings, crosshead bearings and pinion shaft bearings. Replace with new

if necessary.

3. Check all gears’ wear, if severely worn out in one face, the crankshaft and pinion shaft may be

turned to use the gear’s other unworn face.

10.5 Other Points for Attention in Maintenance

1. Wipe the taper face clean before installing the piston and extension rod clamps.

2. While replacing the cylinder liner the liner seal rings must be replaced together.

3. When the pump was shut down during winter or temporarily shut down for more than 10 days,

valve cavity and cylinder liner have to be washed after mud fluid inside being drained.

4. Close all inspection covers well to prevent the oil from being contaminated by sand or dirt.

5. The pulsation dampener will be charged only with compressed nitrogen of inert gase or

compressed air. Do not charge with oxygen or hydrogen or other easily-burning and explosive gases.

Checklist for Daily Maintenance

Table Ⅷ
Period Check points What to do for maintenance
Daily 1 Stop the pump to check oil level. Replenish oil to prescribed level.
Check the pressure gauge reading of lube oil pump to make sure it is
Daily 2
proper.
Daily 3 Check whether the pressure of pulsation dampener is normal.
Fully refill the water tank of spray pump when cooling lubricant fluid is
Daily 4
insufficient. Replace when the fluid is contaminated.
Check frame cylinder liner bore. Clean when there is much mud and oil
Daily 5
settling down.
Check every 4 hours whether the cylinder head is loose. Apply grease to
Daily 6
threads when tightening.
Daily 7 Observe the leakage on piston, lineer. Replace in case of heavy leaksge.
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 OPERATION MANUAL FOR LGF-500 Drilling Pump

Loosen piston rod clamp once each day and tighten the clamp by turning
Daily 8
the piston rod 1/4 circle.
Check every 4 hours whether the valve bonnet is loose. Apply grease to
Daily 9
threads when tightening.
Daily 10 Check the reliability of safety valve.
Check whether the precharged pressure on discharge surge dampener
Daily 11
is ok during pump stoppage.
Observe warning hole. Replace timely the relevant seal rings (3
Daily 12
locations) in case of mud draining out.
Tear down cylinder head, valve bonnet to remove mud and coat with
Weekly 13
compound calcium based molybdenum disulfide grease.
Weekly 14 Check the inner sleeve of guide. Replace when wear is too much.
Check the suctionand discharge valve body, valve seat, valve seal
Weekly 15
rubber. Replace the damaged with new one.
Check whether the locking nuts of piston have been eroded or damaged.
Weekly 16
Replace if damaged (Normally to be used 3 times)
Check whether strainers of lubrication system have been blocked. Clean
Weekly 17
when blocked.
Rotate off drainage plug to discharge contaminants and water
Weekly 18
accumulated in oil reservoir.
Check whether bolts of fluid end are loose or damaged. To tighten or
Monthly 19
replace.
Check the seal ring in packing box. Replace if worn out or at least every
Monthly 20
3 months.
Check whether strainer in discharge line has been blocked. Clean when
Monthly 21
blocked.
Discharge every 6 months the contaminated oil in power end oil reservoir
Monthly 22
and crosshead oil settling chamber and clean.
Check the wear status of crosshead surface. Rotate crosshead 180° to
Yearly 23
be reused when necessary.
Check whether the guide sleeve is loose and crosshead clearance is up to
Yearly 24
requirement. To inspect and adjust when necessary.
Check the wear status of pinion shaft and master gear rim surface.
Yearly 25
Exchange the surface for use when necessary.
Check whether pinion shaft and crankshaft assembly are perfect. Take
Yearly 26
action when there are abnormal findings
Check whether bearings of power end have been damaged. Replace if
Yearly 27
damaged.
Check the seal on the rear cover and crankshaft end cover. Replace in
Yearly 28
case of bad seal.

11. Possible Failures and How to Eliminate

If fault occurs during mud pump operation, take timely action to find out the reason and to eliminate it;

otherwise, mechanical members may be damaged to affect adversely drilling operation.

Table Ⅸ
Faults Caused by Troubleshooting methods

1. Suction manifold is not 1. Tighten all suction flange bolts

1. Gauge pressure drops, mud
sealed tightly and air or replace gaskets.
flowrate comes down or no
entered into pump. 2. Stop pump and clean the filter
mud fluid flows.
2. Suction filter screen clogged screen.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

2. Fluid discharges are non 1. Replace damaged piston:

uniform and pulsations are
1. One piston or one valve open valve bonnet and check
subject to sudden change,
gauge pressures vary severely worn or damaged. valves.
greatly, a wheezy sound can
2. Air entered into cylinder. 2. Check the tightness of suction
be heard in suction
manifold. manifold and valve bonnet.
1. Tighten piston nuts.
1. Loose piston nut
3. Severe knock could be 2. Tighten cylinder head gland.
2. Loose cylinder head gland.
heard in liner. 3. Check reasons for poor
3. Poor suction.
suction.
4.4. 4. Leak at indicator hole of
1. Loose valve pot cover and 1. Tighten valve pot cover and
valve bonnet or cylinder
cylinder head. cylinder head.
head and liner sealing
2. Seal rings damaged. 2. Replace damaged seal rings.
places.
1. Charging connector is
blocked. 1. Remove dirt in connection.
5. Discharge dampener can
2. Dampener’s airbag is 2. Replace damaged airbag.
not be charged or leaks down
broken. 3. Repair or replace the
soon after charging
3. Needle stop valve was not damaged needle stop valve.
tightly sealed.
6. Engine is heavily-loaded1.R Discharge filter clogged Remove filter screen, and clean.
7. Power end bearings, 1. Oil pipe or holes clogged 1. Clean oil pipe and holes.
crosshead overheating 2. Lube oil is too dirty or 2. Replace old with new oil.
contaminated. 3. Repair or replace bearings.
3. Roller bearings are worn out 4. Use proper quantity of lube oil.
ordamaged.
4. Lube oil is excessive or
insufficient.
1 Crosshead guide sleeve 1 Exchange the surface of
8. Abnormal noises can be crossheadguide sleeve or
worn-out.
heard in power end. replace guide sleeve.
1 Worn bearing.
2 Loose crosshead guide 2 Replace bearing.
sleeve. 3 Tighten guide sleeve screws.
3 Water hammer in fluid end. 4 Improve suction performance.

Note ： Except for above mentioned faults, other abnormities may be found.Under this
circumstance, try to find out the reason as per fault location. The mud pump can be properly in
operation only after the fault reason has been searched out and eliminated.

12. Long Term Storage

1. If a mud-pump will not be used for a long period, it should be mothballed.

2. Before mothballing, all fluids in the fluid end should be drained out, remove all dirt, wash with water

and wipe clean.

3. Drain out completely lube oil in power end gear box, and remove all accumulated dirt.

4. Coat all machined surfaces on all bearings, crosshead, gears, piston rod, extension rod etc with

heavy duty oil.

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

5. Coat machined surfaces of all components in fluid end with lubricant.

6. Block all suction and discharge flanges with blind plates.

7. Seal tightly all crosshead hole end cover, back cover, inspection-opening cover etc.

13. Special Tools List For LGF—500 Mud Pump,

delivered together with the pump
NO. part NO. part name QTY./ unit
1 LGF3051-25.01G sleeve 16 1
2 LGF3051-25.02.00G hydraulic valve puller 1
3 LGF3101-25.01G sleeve 50 1
4 LGF3101-25.02G sleeve 55 1
5 LGF3101-25.03G sleeve 60 1
6 LGF3101-25.05G connector 1 1
7 LGF3101-25.06G extension rod 8 1
8 LGF3101-25.07G extension rod 24 1
9 LGF3101-25.09.00G handling tool for valve rod guide 1
10 LGF3101-25.10.00G puller for cylinder pusher 1
11 PSH-Ⅱ manual oil pump（70MPa） 1
12 inner hexagon wrench 12 1
13 inner hexagon wrench 14 1
14 inner hexagon wrench 16 1
15 LGF3161-25.08.00 puller for bulkhead of cylinder cover 1
16 LGF3161-26.01.00 Rod of cylinder cover 1

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 OPERATION MANUAL FOR LGF-500 Drilling Pump

14. Spare Parts List for LGF—500 Mud Pump

NO. part NO. part name QTY./ unit

1 GB/T3452.1-1992 double-lip oil seals 5.87″*7.125″*0.625″ 2
2 GB/T3452.1-1992 “O”type ring：95*5.3G 3
3 LGF3051-04.18G double-lip oil seals 6
4 GB/T3452.1-1992 “O”type ring：75*5.3G 3
5 LGF3051-05.04G cylinder liner seals 6
6 LGF3051-05.09G valve bonnet seals 3
7 LGF3051-09G seal gasket 2
8 GB/T3452.1-1992 “O”type ring：355×5.3G 3
9 GB/T3452.1-1992 “O”type ring：35×3.55G 3
13 LGF3101-28.11G shear pin 10
11 LGF3101-27.01G seal gasket R39 1
12 LGF3101-28.06G cushion 1
13 LGF3101-28.03.00G piston assembly 1

14 LGF3051-05.26G fixed clamp 3

15 GB/T3452.1-1992 “O”type ring：150×7G 3

16 LGF3051-04.06G oil seal ring 3
17 GB/T3452.1-1992 “O”type ring：230×7G 3
18 GB/T3452.1-1992 “O”type ring：71×5.3G 3
19 GB/T3452.1-1992 “O”type ring：165×7G 3
20 LGF3051-05.20G Piston sealing ring 3
21 LGF-3161-22.06G seal gasket R27 2
22 seal gasket R35 1

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