WH1612

Triplex Pump

Operating and Maintenance

Manual

Gaffney-Kroese Supply

WH1612-241

6500 Brittmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343
832-872-6500 1-866-946-5333 FAX: 832-782-6627
www.letourneau-inc.com/drilling pumps@let-tech.com
This page is blank.

6500 Brittmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343
832-872-6500 1-866-946-5333 FAX: 832-782-6627
www.letourneau-inc.com/drilling pumps@let-tech.com
6500 Brittmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343
832-872-6500 1-866-946-5333 FAX: 832-782-6627
www.letourneau-inc.com/drilling pumps@let-tech.com
OMM-04 2007
 Table of Contents

Preface ......................................................................................................... 1

Warning ........................................................................................................ 2

Glossary........................................................................................................ 3

Installation..................................................................................................... 5

Operation ...................................................................................................... 9

Maintenance ............................................................................................... 14

Disassembly (Fluid End) ............................................................................. 19

Assembly (Fluid End).................................................................................. 22

Disassembly (Power End)........................................................................... 29

Assembly (Power End) ............................................................................... 35

Torque Specifications ................................................................................. 41

Belt Tensioning ........................................................................................... 42

Special Tools .............................................................................................. 43

Troubleshooting .......................................................................................... 44

6500 Brittmoore, Houston, Texas 77041 PO Box 41343, Houston, Texas 77241-1343
832-872-6500 1-866-946-5333 FAX: 832-782-6627
www.letourneau-inc.com/drilling pumps@let-tech.com
Preface
This manual provides instructions to install, repair, maintain, or adjust a
LeTourneau Technologies (LTI) mud pump. The information is intended for
operators and service personnel who are familiar with drilling equipment. It
will not cover every situation that may be encountered.

Each pump is a combination of a basic design and optional features. This

manual provides information on all the optional features. Because of this, some
of the features described in this manual may not be present on a specific pump.

Always use good, sound mechanical practices and safety precautions.

Specifications are in accordance with engineering design and should be

followed in all repairs. Operation and maintenance information for equipment
other than LTI products is taken, in part, from the various manufacturers’
service manuals. In the event of conflict between this manual and component
manufacturer’s information, the manufacturer’s information will take
preference over this manual unless specifically stated otherwise.

The material used in the construction of the pump is satisfactory for use in a
sour gas (Hydrogen Sulfide) environment if the drilling fluid condition is
maintained as specified in NACE Standard MR0175. This NACE standard
specifies one of the following:

• Maintaining a pH 10, or higher, to neutralize Hydrogen Sulfide (H2S)

in the drilling mud
• Using chemical sulfide scavengers
• Using a drilling fluid in which oil is the continuous phase

Failure to control the drilling fluid as specified can result in sulfide stress
cracking of certain components and result in serious personal injuries or death.

LTI reserves the right to change, discontinue, or modify pump models at any
time without notice and without incurring any obligation.

1
 Warning
Before Servicing Pumps

1. Read manufacturer’s manual prior to operation or servicing the pump.

2. Shut down or disengage the pump power source. Failure to shut

down power before servicing can result in serious personal injury
and property damage.

3. Shut down all pump accessory equipment.

4. Relieve, or bleed off, all pressure from the pump fluid module(s).
Failure to relieve pressure before servicing can result in serious
personal injury

5. Do not use either a high-pressure air or a nitrogen source for

charging the suction dampener. Use only a hand-operated air pump.
Over-pressure can result in serious injury to personnel and .cause
damage to components.

6. Do not pipe the relief valve bypass line into the pump suction
system piping. High-pressure surges can result in serious injury to
personnel and .cause damage to components.

7. Always use the rig hoist, lifting appliance, or jib crane to lift items
over 40 lb. Failure to use such devices could cause personal injury.

8. Always wash the inside of a pump fluid end if the pump is to be idle
for an extended period. If the mud is stagnant and confined,
microbiological action in certain drilling muds can produce harmful
quantities of sulfides.

2
 1. Discharge Manifold
Provides connections for the strainer cross including
the pulsation dampener, pressure relief valve, and
discharge pressure gauge
2. Chain Drive
Multiple strand roller chain running on sprockets that
delivers power from the drive motors to the pump
power end
3. Clean Out Plugs—Crosshead Compartment
Magnetic plugs on both sides of the pump to drain off
contamination that has settled in the compartment
4. Pulsation Dampener
Pressure container mounted on the discharge manifold
for smoothing the pulsations in the discharge piping
5. Discharge Strainer Cross
A flanged cross with a strainer screen that is connected
to the discharge manifold that removes large pieces of
debris from the pump discharge
6. Electric Drive Motors
DC traction-type motors or AC variable frequency
motors
7. External Lube Oil Pump
Electric powered pump providing lubrication to the
pump
8. Fluid End
Mud pumping equipment made up of three modules,
(fluid cylinders): suction and discharge valves, suction
and discharge manifolds, and liners and pistons
9. Gear Case Cover
Cover for the pump crankcase that allows access to the
crankshaft, pinion shaft, and internal lubrication pump
10. Inspection Cover Crosshead Compartment
An opening for access to the crossheads, crosshead
guides, wrist pins, and crosshead bearings.
11. Inspection Cover—Gear Case Cover
An opening used to inspect the pinion and gear tooth
contact.
12. Liner Wash Heat Exchanger
A water-cooled heat exchanger to cool the liner wash
fluid
13. Liner Wash Pump
An electric powered centrifugal pump circulating liner
wash and cooling fluid from the liner wash tank to the
liner spray nozzles
14. Liner Wash Tank
Storage for the liner wash fluid that is divided into
two sections, a settling section, and a reservoir
section
3
15. Lube Oil Heat Exchanger
A water-cooled heat exchanger to cool the crankcase
oil
16. Lube Oil Filter
An external filter to clean the lube oil
17. Oil Level Dipstick
An oil level check—typically on the left side of the
pump—to check the oil level when the pump is idle
18. Power End
Mechanical conversion of rotary input motion to
reciprocating output for powering the pistons
19. Reset Relief Valve
A relief valve that must be reset manually. This
valve is installed in the discharge piping as near the
pump discharge manifold as possible with the valve
discharge connected to the mud tank.
20. Rotation Fitting
A 2-in. hex bar attached to both ends of the pinion
shaft and used to manually rotate the pump during
service
21. Service Crane
A light duty crane mounted on the pump for
handling heavy equipment, liners, etc. when
servicing the pump
22. Suction Dampener
An elastomeric device to smooth suction pressures
23. Suction Manifold
A distribution pipe bolted to the inlet openings of the
fluid end modules to supply drilling fluid to the fluid
end. This manifold may contain the suction
dampener.
24. V-Belt Drive
Multiple, high-capacity 8V-size belts arranged in
banded sets and running on V-belt sheaves that
transmit power from the motors to the pump power
end
25. V-Belt Motor Mount
A mounting frame over or behind the pump that
supports the electric drive motors and provides the
means to move the motors or to adjust tension in the
V-belts
4
Installation
Preparation
Proper pump installation requires thought and planning before the rig-up is
made. Use the following guide to help plan installation and avoid unnecessary
and expensive corrections to piping, pulsation dampener mounting, and
equipment tie down after installation.

Foundation
Setting the Pump
Make sure to set the pump level. If the pump is not level, the lubricating oil in
the power end will not be distributed properly when the pump is running

Temporary Support
Use plank or beam foundation matting to temporality support the pump. Be
sure that the pump is evenly supported under its entire length to prevent
unnecessary strain on the frame.

Fixed Support
For fixed or permanent installations, the foundation must be level and evenly
support the pump under its entire length.

• Follow the mounting locations shown on the assembly drawing.

• Shim the support points as necessary. Do Not draw the frame down to the
support
• Lock the pump down evenly to prevent unnecessary strain on the frame.

Suction Piping
Suction Dampener Location
The LTI flanged suction dampener must always be installed directly inside the
pump suction manifold.

Note
When a welded in suction line dampener is used, it must
be mounted as close to the pump suction manifold flange
as possible. To insure satisfactory performance, never
place either valves or turns between the suction line
dampener and the pump suction manifold inlet.

Suction Dampener Pressure

Precharge the suction dampener to 15 psi. Adjust the dampener pressure
charge pressure, either up or down, as necessary to obtain the smoothest
operation for the specific suction conditions of the pump. See Suction Piping
Arrangement.

5
Suction Piping Arrangement
When equipped with a properly installed suction dampener, LTI triplex mud
pumps will satisfactorily operate without a charging pump in the following
conditions:

• The fluid level in the tank is higher than the top of the liners.
• The pumped fluid has a low viscosity.
• The suction line is short and straight with a diameter that is at least as
large as the diameter of the pump’s suction manifold.

When these conditions are not met, the operator must use a dual piping design
that permits both natural and charged suction operation.

Natural suction piping must meet the requirements previously stated. The line
from the charging pump discharge to the pump suction manifold may violate
these restrictions if the suction dampener is installed directly inside the pump
suction manifold.

The optimum suction manifold pressure is 50–70 psi to achieve maximum

volumetric efficiency and to maximize expendable parts life.

Common Suction Manifold

Two or more pumps may have their suction connections made to a common
manifold. The common manifold must have a cross-sectional area greater than
the sum of the individual pump inlet areas. If a manifold with a smaller area is
used, the pump’s efficiency will decrease.

Suction Line Valves

Always use full opening valves such as a gate- or butterfly-type valves. Do not
use a restricting type of valve such as a plug valve, because those types of
valve will restrict the flow and reduce the efficiency of the pump.

Pulsation Dampener
Always use a discharge pulsation dampener in the discharge line of each
pump to prevent harmonic vibration from damaging the discharge piping.
Mount the dampener on a discharge cross that is flanged directly to the
discharge manifold. See the Bolt Torque section for bolt torque.

Pressure Relief Valve

Provide a relief valve for the piping between the pump suction inlet and the
charging pump discharge. This valve should be set at approximately 50 psi
and should be mounted in the top of the line near the suction dampener. The
relief valve provides protection for the charging pump and suction dampener
in the event of a high-pressure surge in the suction line.

6
Discharge Piping

Discharge Cross
The discharge piping can be simplified by using the forged discharge cross (1)
available from LTI as optional equipment. This forged cross provides two
outlets for mud lines (2) and a mounting for the discharge pulsation dampener
on top of the cross. The cross also incorporates a side connector for mounting
a pressure gage. The complete assembly can be flanged directly to either side
of the pump (1 or 4) ,and it has an integral support from the cross to the pump
frame. See the Bolt Torque section of this manual for bolt torque.

Strainer Cross
The optional LTI discharge strainer cross (3) adds an easy access from the
strainer to the discharge cross described above. The strainer should be
checked and cleaned at least once a month. Do Not add a strainer cross if a
pressure relief valve has been installed.

Pressure Relief Valve

Warning
The relief valve must not be connected to the strainer cross
because a plugged strainer could prevent the relief valve from
sensing and relieving excessive pump discharge pressures,
leading to serious injury to personnel and equipment. In
addition, the relief valve and its bypass line could interfere with
the removal of the strainer clean-out flange needed for periodic
cleaning of the strainer.

7
Always provide a full-opening, manual reset type of pressure relief valve to
protect the system against damage from over pressure. The pump discharge
manifold end opposite the discharge cross can be used for connecting a high-
pressure relief line and a bypass line.

Do Not put any type of shut-off valve between the relief valve and the
discharge manifold.

When a pump has dual pulsation dampeners, install the relief valve on the side
connector (3) without the strainer cross.

The relief valve discharge line should be the same size as the valve discharge
opening. The piping should be short, straight, securely anchored, and provide
an escape path for the fluid to go back to the mud tank. The discharge line
must slope downward at least ¼ in per 12 in. to prevent solids from settling in
the line.

The following are recommendations for setting the actuation pressure of a

Retsco, RR, and Oteco relief valves.

• RR Valve
The RR Valve has a variance of ±150 psi, regardless of the actuation
pressure. The actuation pressure should be set to 150 psi greater than the
maximum pressure rating of the liner used.
The last mark on the indicator’s scale is 7500 psi, and a quarter turn of the
adjusting nut represents approximately 500 psi. At a maximum operating
pressure of 7500 psi, the valve should be set to 7500 psi on the indicator’s
scale and then the adjusting nut should be rotated 1/8 of a turn..
• Retsco Valve
The Retsco valve has a variance of ±3%, regardless of the actuation
pressure. The actuation pressure should be set to 1.03 times the maximum
pressure rating of the liner used.
The last mark on the indicator’s scale represents 8000 psi. If the operating
pressure is 7500 psi, then the actuation pressure should be set to 7725 psi.
• Oteco Valve
Oteco valves are pressure relief valve that use s hear pins to determine the
operating pressure. The nominal operating pressure listed on the valve
nameplate was determined in laboratory conditions using Oteco shear
pins. The actual operating pressure of the valve will vary. Refer to the
Oteco Manual in the Accessory Catalogues for more information.

All adjustments should be made with the valve at normal operating

temperature.

8
Operation
Prior to Start Up
Pulsation Dampener
Before initial start up, charge the dampener to approximately 15 psi to provide
a cushion for the diaphragm when the charging pump is started.

Power End Lubrication

Note
When starting a new pump for the first time or starting up after
storage, open the inspection covers and pour oil into the pinion
bearing oil trough and the crosshead oil reservoir. This fills the
internal oil reservoirs and ensures immediate lubrication. For those
pumps with an external lube pump (electric), make sure the pump is
operational and pumping oil through all the internal lube lines.

Remove the drain plugs from both the crankcase (18) and crosshead
compartments (19) and drain any moisture or contamination that has
accumulated.
Fill the pump power end with Extreme Pressure Gear Oil. Refer to the table
below and select an oil meeting the recommended AGMA number
specification for the ambient conditions.
Temperature Lubricant
AGMA No.7 EP or ASTM/ISO-VG Grade460
+50°F to +155°F (Viscosity 2214-2719 SSU at 100°F)
Non-Corrosive, Anti-Foaming Gear Lube
AGMA No.6 EP or ASTM/ISO-VG Grade 320
+20°F to +100°F (Viscosity 1533-1881 SSU at 100°F)
Non-Corrosive, Anti-Foaming Gear Lube
AGMA No. 2 EP or ASTM/ISO-VG Grade 68
-20°F to +60°F (Viscosity 318-389 SSU at 100°F)
Non-Corrosive, Anti-Foaming Gear Lube

9
Pump Oil Capacities
With the pump at rest, use the dipstick (17) to measure the oil. The oil level
should fall between the marks on the dipstick. These marks correspond to the
centerline of the lowest eccentric bearing roller with a connecting rod throw at
its lowest point during rotation.
Pump Oil Capacities
Pump Maximum Capacity
Type Horsepower Rating (U.S. Gallons)
440 35
Triplex 770
55
(Light) 1000
2200 130
250 20
440 35
550 50
600
55
Triplex 800
(Heavy) 1000
110
1100
1500
130
1700
3000 225
600 42
Quintuplex 100
75
1200
Chain Drive Lubrication
Fill the chain case on chain-driven pumps with a good grade of nondetergent
motor oil. Use the following table as a guide to select the proper viscosity of
oil for the ambient air temperature at the pump.
Viscosity Guide
Temperature SAE Viscosity
+20°F to +60°F 20W
+40°F to +120°F 30W
+60°F to +140°F 40W
Drive Alignment
Make sure that the input drives to the pump are properly aligned. LTI
recommends using either a laser alignment tool or a straight edge. A straight
edge laid across the either the edges of the sheaves or the sprockets should
contact both edges of both sheaves or sprockets in the drive. LTI can provide
a small, convenient laser alignment tool, (P/N 108-1086) to facilitate drive
alignment.

10
Liner Spray Lubrication

Note
To effectively cool the piston and the liner, the temperature of the
coolant must be below the temperature of the drilling mud. In some
circumstances, it may be necessary to provide an external means to
remove the heat from the coolant fluid.

Fill the liner piston spray system with clean water and a good synthetic fluid,
such as Castrol Syntilo 9951, an equivalent, or water-soluble oil. A synthetic
fluid is best when mixed with clean water.
Depending on the corrosiveness of the water and/or drilling mud, a water-
soluble oil can also be used for cooling. LTI recommends a mixture of 10-
20% synthetic fluid or soluble oil with clean water, depending on the size of
the liner spray wash volume tank.
If water is used without a mixture of oil, the operator must exercise greater
care and perform more maintenance to prevent heat and corrosion damage to
the parts in and adjacent to the piston liner chamber. Coating the clamps and
all exposed surfaces with a thread compound will minimize the effects of
corrosion.
When a liner spray manifold system is used, the operator must make sure that
the spray nozzles are properly positioned for the size of the liner being used.
The spray system must start either before, or at the same time, as the mud
pump to prevent damage to the piston and liner.
Liner Spray Pump
An electrically driven or a V-belt driven centrifugal pump is used on all
triplex mud pumps for supplying coolant to the liners and pistons.

Caution
The seal on the centrifugal pump will be damaged if the pump is
allowed to run dry or to cavitate. Maintain a flooded suction to the
centrifugal pump at all times to prevent damage to the equipment.

The centrifugal pump oil reservoir must be kept filled to the proper level with
SAE 20 motor oil to protect the oil-lubricated bearings.
Fluid End Check
Check the fluid end to verify that
• the liners and pistons have been properly installed,
• the rod and liner clamps have been tightened,
• the valves have been installed,
• the valve covers have been tightened.

11
 Line Valves and Charging Pump
Open all valves in the suction and discharge lines and check to be sure that the
suction charging pump is starting either at the same time or before the start of
the triplex mud pump. Never start the mud pump ahead of the charging pump,
because this will result in cavitation, incomplete filling, and damage to the
fluid end parts.
After Start Up
Pump Speed
Bring the pump up to speed gradually. This allows the flow velocity of the
fluid in the suction line to match the flow requirements to the pump without
cavitation.
Natural and Charged Suction Operation
The maximum pump speed when operating with a natural suction is limited
only by the pump’s ability to completely fill during the suction stroke. This
limiting speed will be different for each installation, because it depends on the
design of the suction piping and available head as well as the condition of the
mud; i.e., weight and/or amount of entrained air or gas.
The operator can easily determine this limiting speed by simply listening to
the pump. As the limit is approached, the pump will begin to knock, indicating
cavitation and incomplete filling. At this point, the suction charging pump
should be brought into the system, until operating conditions change and a
natural suction can again be used.
Suction Dampener Charge and Adjustment

Warning
Use a hand-operated air pump to charge the suction line pulsation
dampeners Do not use a high-pressure air source or nitrogen bottle.
Charging the suction dampener with high-pressure sources can
result in serious injury to personnel and equipment damage.

Before the initial startup, use a hand-operated air pump to charge the
dampener to approximately 15 psi. This will provide a safety margin to
prevent accidental damage to the diaphragm when the charging pump is
started. The proper charge and final adjustment must be determined with the
pump operating. The dampener charge level will be different for charged
suction operation and for natural suction operation. This is readily adjusted
using an ordinary, hand-operated air pump.

12
Lubrication

Note
Do not operate the pump without the external lube system, if this
system is installed.

V-Belt Drive
Listen to the operation of the drive under load. Squealing or increased noise
above normal condition indicates that the belts need adjustment. The
adjustment of new belts should be checked after several hours of operation,
because the new belts will seat in the drive and lose tension.
Check the sheave alignment during the belt tension check. A straight edge or
string across the sheave should touch each sheave at both the near and the far
edges. LTI recommends using an alignment tool for proper adjustment and
alignment.

13
Maintenance
Regular inspection and maintenance of the pump drive, power end, and fluid end will result in
considerable savings by detecting and correcting minor problems before they become major repairs.
Initial Operation
A new pump requires expanded maintenance and inspection procedures during the first 500 hours of
operation in addition to the regular daily inspection and maintenance procedures.

Magnets
• Clean the magnets in the external oil strainer every 50 hours or until no particles can be see
on the magnets through two inspection intervals.
Lubricating Oil
• Change the lubricating oil at either 250 hours or 3-months of operation, whichever occurs
first during the initial operating period.
Pinion and Gear
• Check for pitting during the initial operation period.
Some corrective pitting of the gear is expected during the initial operation period. These
pits should be small and circular and dispersed along the pitch line of the gear teeth. They
should not expand and form larger, single pits. Pitting activity should slow to a halt during
the initial operation period.
Daily
• Inspect the pump to ensure that all the threads that are exposed to the atmosphere are
coated with rust inhibitor.
Power End
• Check the pressure gages on the external lube oil filter.
• Clean the strainer and the strainer magnets if the pressure differential between the gages is
greater than 15 psi when the pump is at operating temperature.
• Check the oil level in the pump end daily. The level should be checked with the pump at
rest.
Chain Case
• Check the oil level in the chain case of a chain driven pump daily. The oil level in the
chain case should be checked with the pump operating.
Belt Drives
• Check the belts on the drives.

Caution
The pump should be stopped and in a safe condition before
tightening belts.

• Tighten the belts according to the procedures in the Belt Tensioning section of this manual
if slipping or squealing is noticed.
• Always check the sheave alignment when tension is adjusted.
Auxiliary Pumps
• Lubricate the shaft and packing as instructed by the manufacturer.
14
 Pistons and Liners
• Check the condition of the liners and pistons.
A small amount of the drilling fluid is washed from the liner on each stroke. This does not
necessarily indicate worn out pistons or liners. Smooth wear on the liners normally
indicates smooth wear on the pistons. This combination should run until the drilling fluid
bypass is visible on each stroke or becomes excessive.
Liner Chamber Coolant
• Check the liner-piston coolant daily.
• Add as required and replace if dirty.
• Flush the sump with fresh water before adding clean coolant.

Note
Dirty coolant will increase wear of the liners and pistons and will
shorten the life of the coolant pump.

Spray Manifold
• Check the spray nozzles on the liner spray manifold daily.
• Clean as necessary to ensure an adequate coolant-lubricant supply for the liner and piston.
Rod and Liner Clamps
• Recheck the liner and rod clamps for proper tightness after the first few hours of operation
following assembly.
This allows the taper locking assembly to become seated. Proper tightening will ensure
minimum movement of the rod components.
Valve Covers
• Check to make sure the valve covers are tight after the first few hours of operation.
Suction Dampener
• Check the pressure.
It must be correct for the operating condition, approximately 15 psi.
Pony Rod Seals
• Lubricate the pony rod seals with No. 1 multipurpose lithium grease while the pump is in
operation.
Pump grease until it becomes visible on the inside diameter of the seal. Make sure that the
grease is around the entire seal.
Semimonthly
Valve Cover Threads
• Remove all valve covers and carefully clean all mud and debris from the threads on the
cover screw and in the bolt ring.
• Completely grease the cleaned threads with a drill collar thread compound.
It is important that an anti-seize compound be used to provide the necessary protection
against corrosion, galling and seizing.
Do not use an ordinary tool joint thread dope, because these materials do not effectively
protect the joint.

15
 Valve Cover Plug and Packing
• Clean and coat the top of the valve plug with the same compound used on the valve cover
threads.
• Inspect the valve cover packing and carefully clean and coat the shoulder in the cylinder
above the packing before installing the plug.
This is necessary to prevent cocking of the plug and to allow a full metal-to-metal lock up
of the cover.
Valve Guide Bushing
• Inspect the bushing in the valve stem guide and replace if it is visibly worn.
A worn bushing will cause increased valve wear.
Valve and Seats
• Check the valves and seats for wear.
• Replace cut or worn inserts.
Piston Hub Seal
This is a compression seal that fits against the flange and radius on the piston rod.
• Check to make sure that the seal is not altered or damaged.
• Make sure that the seal is correctly placed in the piston hub groove.
Piston Rod Lock Nut
• Replace the piston rod lock nut if it has been damaged or corroded, or if the locking nylon
has lost its ability to effectively grip the threads.
• Replace any nut that has been used three (3) times.
Monthly
Cross Strainer
• Clean the strainer sleeve
Note
The cross strainer is an equipment option.
Studs and Nuts
• Check and tighten all of the fluid cylinder studs and nuts.
This includes the valve cover bolt on rings, cylinder to frame studs, liner pilot bushing
studs, and discharge to suction studs.
Gaskets and Seals
• Inspect the power end for badly leaking gaskets or loose capscrews.
• Replace as required.
Six Months
Power End Lubrication
• Drain and clean the power end oil sump and the settling area under the crossheads.
• Refill with the proper grade of EP gear oil. See Table in preceding section for grade.
Lubrication System Magnets
• Clean the magnets in the oil pump strainer area.
Lubrication Lines
• All lines should be in place, continuous, and free of obstructions.

16
Twelve Months
Clearances
• Check the clearance in all bearings, the crossheads, and the main gears.
• Record this data for future reference.
• Make the required repairs if the bearing clearance exceeds two times the maximum
installed clearances,
If the clearance has increased abnormally, a more thorough inspection is indicated to
locate the source of the wear. For installation clearances, see parts catalogue.
Crosshead Guides
• Check the crosshead guides for grooves.
Grooved crosshead guides indicate improper lubrication.
• Check the lubrication system and the condition of the crosshead extension rod seals.
• Replace if severely worn or scarred.
Bolting
• Check the tightness of the mainframe mounting bolts, and crosshead pin retainer bolts.
• Check the safety wires on all the bolts. If wires are broken, determine the cause and
correct.
• Tighten loosened bolts.
• Replace broken safety wires.
• Check the tightness of the main bearing cap bolts.
For pumps with Super Nuts the torque for the tightening bolts is stamped on the top of the
nut. For others, refer to the Torque Specification section.
Main and Pinion Gears
• Inspect the condition of the main gear and pinion gear teeth.
As stated previously, some minor pitting may occur during the initial operation period of
the pump. This initial, or corrective, pitting should be light and limited to an area near the
pitch line of the gear teeth and extend across the length of the teeth. Scoring, significant
pitting, or continued increase of pitting should be thoroughly inspected and the source of
the problem removed.
• Replace parts that are worn beyond the recommended clearance.
STORAGE
If the pump is to be idle for longer than one week, it should be prepared for storage.

Power End
• Remove the power end covers.
• Drain and clean the main sump and settling tank.
• Coat all bearings, finished surfaces, and the entire inside surface of the power end with a
rust inhibiting oil.
• Replace the covers.
• Raise the fluid end of the pump and block it up so that the pump slopes downward toward
the power end.
• Replace the main sump drain plug with a 90° elbow.
• Point the elbow down and cover the opening with a wire mesh screen.
This will permit air circulation and prevent condensation build-up.
Fluid End
• Remove the fluid end valves, piston rods, and liners.
17
 • Clean the inside of the fluid ends and all parts.
• Coat the entire fluid end, valves, and parts with a rust inhibiting oil.
• Clean the liner spray system and settling tank.
• Put clean oil into the liner spray pump to prevent rusting.
• Coat the tank and inner spray parts with a rust inhibiting oil.
Periodic Inspection
• Inspect the pump and rotate the gears once a month.
• Recoat with a rust-inhibiting oil.
After Storage

Caution
Any pump that has been in storage, either after use in the field or as
shipped from the plant, will need an inspection to make sure it has
not been damaged in any way and that all parts are properly in place.
Failure to observe the following points can result in serious injury to
personnel and serious damage to the equipment.

Power End
• Remove all of the covers on both the power end and the fluid end.
• Clean and inspect all of the parts and the finished surfaces.
• Check all of the bearings to make certain they are clean and in good condition.
• Fill the power end to the proper level.
Use a clean EP gear oil of the proper viscosity. See Table in preceding section
• Make sure oil is poured into the crosshead reservoir and is worked into all of the bearings
Fluid End
• Check the valves, pistons, liners, and all fluid end parts and make sure they are properly
installed and in good condition.
• Carefully tighten all of the bolts, nuts, studs, working connections, and covers.
• Fill the liner spray system with a clean coolant.

18
Disassembly (Fluid End)

Fluid End Modules

Suction Module/Discharge Module
The suction module portion (2) of the two-piece fluid modules can be removed
without disturbing the discharge module. The discharge module portion of the two-
piece fluid end can also be removed without disturbing the adjacent modules.

1. Remove the capscrews (7)connecting the module to the suction manifold

2. Remove the nuts (31) from the studs holding it to the discharge module.
3. Remove the suction module (2), the liner (37), piston (38), liner pilot bushing
(17), and the discharge manifold (3).
4. Remove the nuts (29) holding the discharge module to the frame and slide it out
over the suction manifold.
Suction Manifold
1. It is not necessary to remove the suction manifold (4) except for replacement of
the manifold.
2. Remove sufficient suction piping to allow removal of the manifold.
3. Remove the capscrews (7) connecting the manifold to the suction modules and
replace with the new manifold.
4. It is good practice to also replace the gaskets and seals (6) connecting the
manifold to the suction modules and the suction piping.

19
Pistons and Liners
The two-piece piston rod permits removal of a piston without disturbing the liner

Warning
The pressure in the system must be relieved before taking the pistons
and liners apart. Close the shut-off valves in the suction and discharge
lines and open the by-pass line to the mud tanks before attempting
any work on the fluid end modules, liners, pistons, or valves. This
relieves the pressure in the modules and eliminates the danger of
opening a valve cover, or removing a liner clamp while the part is still
under load.

Rod Clamps
The rod clamps (40) are identical and may be removed with ordinary wrenches.

Piston Removal with Liner In Place .

1. Remove the rod clamps (40) and rotate the pump to position the pony rod (44) in
the rear stroke position.
2. Remove the sub-rod (43). Remove the piston rod (21) and piston (38) from the
liner.
Piston and Liner Removal As A Unit
1 Remove the rod clamps (40) and the liner lock ring (18).
2 Rotate the pump to place the pony rod (44) in the rear position.
3 Remove the sub-rod (43).
4 Move the liner (37) out of the liner pilot bushing (17) by using a pry bar between
the collar on the liner and the end of the liner pilot bushing.
5 Lift the piston and liner—as an assembly—up and out of the liner chamber.

Piston Cups
It is possible to change the piston cup (39) without removing the hub (38) from the
rod.

1. Remove the snap ring in the front of the hub and the end plate to permit removal
of the piston cup.
Pistons/Pistons Hub Seal
1. Remove the piston rod nut (20)
2. Slide the straight bore piston hub off the rod.

Note
A pressure-actuated seal fits in a counterbore in the hub and seals
against the radius and shoulder on the rod. Do not alter or damage
this seal.

20
 Liner Sealing Wear Plate
In pumps with wear plates (16), the wear plate is retained by the liner bushing (17).

1. Remove the liner bushing and pry the wear plate from the fluid end to replace the
wear plate.
2. A wear plate seal (15) is located under the wear plate. Always replace this seal.
Valves and Seats
Cover Plug Packing/Valve Stem Guide
1. Remove valve cover screw (11),
2. Remove the valve cover plug (9).
3. Remove the valve cover seal (8) from the fluid end bore.
4. The upper valve stem guide (12) is attached to the valve cover plug. Remove and
replace the upper valve stem guide or the bushing (13) as necessary.
Valves and Seats
1. Lift out the valve spring (45) and valve (46).
2. The valve seat (47) can now be removed.
Always use the hydraulic valve seat puller furnished with the pump when pulling
a valve seat. This avoids the possibility of damaging the fluid end modules with a
torch.

21
Assembly Fluid End

Preparation
Parts should be clean and free of burrs, nicks, and raised metal on the mounting and
sealing faces and bores. All parts used in an assembly should be available and ready to
install before the assembly process is begun.

Refer to the Torque Specification table for proper values

Fluid End Modules

Liner Sealing Wear Plate
For those modules that use wear plates, install the wear plate seal (15) in its
counterbore and follow with the wear plate (16).

Liner Retainer to Discharge Module

Attach the liner retainer (17), pilot bushing) to the discharge module and tighten the
fasteners (24, 30) to the proper torque. (See Torque Specification table.).

Discharge Module to Frame Face

1. Install the discharge module to the frame and tighten the nuts (29) finger tight. Do
not tighten securely at this time.

22
 Suction Module to Discharge Module
1. Install the suction module (2) to discharge module seal wear plate seal (15) in its
counterbore.
2. Slide the suction module (2) over the studs (25) and tighten the nuts (31) to the
proper value.
Liner Bushing
For those modules that use a liner bushing, place the liner bushing (17) over the liner
studs (24, 30) and tighten against the wear plate. Torque the nuts to proper value.

Note
The suction module to the suction manifold
connection must be tightened before the discharge
modules are tightened against the frame.

Tightening Suction Modules to the Suction Manifold

Always use new seals (6) between the suction manifold (4) and the suction modules.
1. Tighten the bolts (7) evenly to the proper torque value.
Tighten Discharge Modules to Frame Face
Tighten the nuts (29) holding the discharge modules to the frame. (See Torque
Specification table.). Use a rotating X pattern of tightening.

Discharge Manifold

Always use new seals (5) between the discharge manifold (3) and the discharge
modules. Tighten the bolts (26, 28) evenly to the proper torque value. (

Pistons and Liners

Pistons and Piston Rods
These pistons have a straight cylindrical bore and are made up to shoulder on the rod.
A seal is used to seal the piston hub against the shoulder on the rod.
1. Install the pistons (38, 39) on the piston rods (21).
2. Make up the shoulder on the rod and make sure the seal is positioned in the hub as
the assembly is made up.

23
Piston Rod Lock Nut

Caution
All piston rod lock nuts must be replaced after being made up three
times. The locking nylon in the end of the nut looses its ability to grip
the threads and prevent back off. Failure to regularly replace the
piston rod nuts can lead to damaged pistons, rods, cylinders, as well
as other parts.

1. Inspect the piston rod lock nut (20) and replace it if the nut shows signs of
corrosion, thread damage, or the crushing effects of tightening with an improper
wrench.
2. Tighten the piston rod nut to the proper value.
Piston and Liner Assembly
1. Grease the inside of the liner (37) and the outside of the piston (38,39).
2. Install the piston in the liner so the piston rod nut and the end of the liner with the
counterbore for the liner seal are on the same end.
3. Grease the outside of the liner.

Note
Use grease for the inside of the liner and the outside of
the piston. Do not use tool joint compounds on the
piston.

Piston and Liner Installation as a Unit

1. Clean and dry the face of the wear plate (16) or module.
2. Install the liner seal (36) in the end of the liner.
3. Coat the inside of the liner retainer (17) with a thin coat of
corrosion-resistant grease.
4. Turn the pump so that the pony rod and sub-rod are in the rear
position. Then slide the liner and piston assembly in the liner
retainer and against the module or wear plate.

Liner Nut
1. Grease the liner retainer (17) and liner nut (18) threads.
2. Slide the liner nut in place over the end of the liner and tighten
by using a brass rod and sledgehammer to strike the hammer
lugs, until tight.

24
Piston Rod and Piston Installations with Liner in Place
1. Rotate the pump so the pony rod (44) is in the rear position
with the sub-rod (43) removed.
2. Grease the piston (38, 39) and the liner bore (37).
3. Install the piston in the liner. Pry bar stops are located in the
bottom of the frame to facilitate this assembly.

Sub-Rod Installation
1. Check the faces of the piston rod (21), sub-rod (43), and pony
rod (44) for upsets, burrs, or any other defects or blemishes.
2. Remove any raised metal on the contacting faces.
3. Position the sub-rod between the pony rod and piston rod.
4. Rotate the pump to bring the connections together.

Piston Rod Clamps Installation

Caution
The rod clamps must be inspected and installed using the
following procedure. Failure to follow this procedure, could
result in serious equipment or part failure

1. Before installation, inspect both clamps and rod ends to make

sure they are free from any cracks, burrs, dings, or foreign
material.
2. Clean any burrs or dings with a flapper wheel or fine grain
grinder.
3. Immediately discard and replace any rod ends or clamps that
show any cracks.
4. With the rod ends clean and inspected, coat the clamps with
Kopr-Kote to resist corrosion.
5. Install the rod clamps at the pony rod-sub rod connection and
sub rod-piston rod connection.
6. Make sure the rod clamps are facing the proper direction. The
arrows should point towards the fluid end.
7. Once the clamps are fitted over the connection, tighten the
bolts evenly, alternating back and forth from one bolt to the
other, to the specified torque value in the accompanying table.

25
 Warning
Do not torque one side to full torque value and then torque the
other side to full torque value. While tightening the bolts,
repeatedly tap both halves of the clamp lightly with a small (3b)
hammer to ensure proper seating. Make sure the ends of the
clamps are not being deformed when compared to the center of
the clamp. See the following figure for the correct and incorrect
clamp orientation.

Thread
Bolt Size Torque Range (Lubricated)
Series
5/8 in. 11 UNC 50-100 ft-lb
7/8 in. 9 UNC 150-200 ft-lb
1 in. 8 UNC 175-225 ft-lb

With new clamps, the average nominal gap between the clamps is ½ in. This dimension is
for reference only and should not be used to determine if a part will or will not work
correctly.

The most important factors are

• there must be a gap between the 2 clamp halves;
• the surfaces must run parallel to each other.
After repeated use and wear, the top and bottom clamps will start coming closer together.
When the clamp halves start to touch, the clamps should be taken out of service and
replaced with new clamps.
Liner Spray Manifold (For Pumps Equipped)
1. Drop the liner spray manifold over the piston rod and slide it
over the end of the liner.
2. Connect the hose to the outlet at the bottom of the liner
chamber. The hose can be connected to either side.

26
Valves and Seats
Valve and Valve Insert
The valve insert is removable and is held in place with a valve lock.
1. Make sure the insert is securely held to the valve. If it is loose,
the insert will rapidly wear and cut (wash) the valve.
2. Replace the valve if a new insert extends more than 1/16 in.
beyond the valve or if the valve is cut (washed).

Valve Seat
1. Make sure that the taper in the module (1) (2) and the outside
of the seat (47) are clean, dry, and free of nicks and burrs at
assembly.
2. Use a valve seat driver to drive the valve seat to obtain an
initial seal.

Note:
Do not strike the valve seat directly.

Valve Spring
1. Install the valve in the seat and center the valve spring (45) on
the valve (46).

Valve Stem Guide

1. Install a new valve stem guide bushing (12) when the old one is
worn enough to permit 1/8” clearance between the valve stem
and guide

Valve Cover Seal

1. Replace the seal if it is cut or broken down at the outer edges.
2. Clean the seal (8) seat in the module.
3. Lightly grease the valve cover seal
4. Place it in the counterbore in the module.

Valve Cover Plug

1. Coat the bottom seating surface and outside of the valve cover
plug (9) with grease.
2. Make sure the valve spring is centered on the plug.
3. Thoroughly coat the top surface of the plug with grease.

27
 Threaded Ring
1. Coat the threads with tool joint compound
2. If a new threaded bolt-on (10) ring is being installed, tighten
the nuts (27) fastening it to the module to the proper torque
value.
3. Use a rotating X pattern of tightening. Fast Change valve
covers (11)
4. Use a 2-ft. bar through the valve cover and tighten with 4
blows of a 16-lb. sledgehammer.

Suction Line Dampener

This dampener is precharged using air.
1. Charge the suction line dampener to 15 psi.
2. Adjust the dampener charge pressure upward or downward as
necessary to obtain the smoothest operation for the specific
suction conditions of the pump. See Suction Piping
Arrangement.

28
Disassembly (Power End)

Pony Rods
Pony Rod Stuffing Box
Remove the bolts (4) mounting the pony rod stuffing box (3) to the diaphragm plate (5).
Slide the stuffing box off the pony rod (7).
Crosshead Diaphragm Plate
1. Unbolt and remove the diaphragm plate (5) and the gasket (6). This
opening is large enough to permit the crosshead (1) to be taken through
the opening and removed out through the liner chamber.
Pony Rod
Remove the pony rod bolts (13) and remove the pony rod (7).
Wrist Pins
Crosshead Pin
1. The wrist pin retainer plates (11) are faced to the outside on the right and
left crossheads.
2. Remove the outer wrist pin retainer bolts (10) that thread into the
crosshead.
3. Leave the bolts (9) in place that thread into the wrist pin (8).
4. Utilize the drilled and tapped holes in the retainer plates to jack the wrist
pin (8) from the crosshead (1).
5. Remove one of the outer crossheads for access to the center wrist pin
and retainer.

29
Crossheads

Crossheads
The crossheads (1) can be removed through the diaphragm plate opening and the liner
chamber. Place a wooden board on the crosshead guide under the connecting rod once
the crosshead has been removed to prevent scoring the guide.

Crosshead Guide
Crosshead Guides
The crosshead guides (2) are bolted to the main frame.

1. Remove the crosshead (1), the four bolts (17), and clamp bars (14)
holding the crosshead guide.
2. If the guide (2) is to be reinstalled, leave any shims, if present, in place.
3. If a new guide or crosshead is to be installed, it requires a a new shim
package and realignment.

30
Main Bearing
The main bearing can be removed without removing the crankshaft from the frame.
Use the following procedure. This same procedure is used to removes the main
bearing from the crankshaft that has been removed from the frame.

1. Disconnect the lube lines.

2. Remove the two main bearing cap nuts (23) and the cap (22).
3. Support the crankshaft assembly to eliminate the downward load on the
main bearings (7).
4. Loosen the main bearing retainer bolts (17) 2 or 3 turns. To make it
easier to remove the bearing, there are grooves under the inner bearing
race with connections on the end of the crankshaft to permit oil
pressurization.
5. When the bearing is loose on the shaft, remove the retainer (12), shims
(13), and bearing (7) from the crankshaft (1).

31
Crankshaft-Gear-Connecting Rod Assembly
Crankshaft Assembly
The gear-crankshaft-connection rod assembly can be removed with careful handling.

1. Remove the wrist pins and slide the crossheads away from the
crankshaft assembly.
2. Support the connecting rods (3) with come-a-longs.
3. Disconnect the lube lines. Remove the main bearing caps.
4. Lift the crankshaft assembly.
See the pump general assembly for clearance dimensions and
approximate weight.
Connecting Rod and Bearings
Connecting Rod and Bearing
Do not remove the connecting rod or bearings unless they are to be replaced, or it is
required for further disassembly. If necessary, use the following procedure to take off
the connecting rods.

1. Remove the outer bearing retainers (8).

2. Remove the roller retainer ring(4) and separate the bearing (4).
This leaves part of the bearing in the connecting rod and part of the
bearing on the crankshaft.
3. Remove the inner retainers (9).
4. Use a hammer and brass rod to tap the bearing parts from the crankshaft
and connecting rod.
Wrist Pin Bearing

Note;
To avoid damage to the bearing (21, do not use a hammer to drive it
from the connecting rod (3).

1. Use an adapter plate slightly smaller than the OD of the wrist pin
bearing (21) to pull or push the outer race and roller assemblyfrom the
connecting rod (3).
2. The inner race of the wrist pin bearing is shrunk on the wrist pin.
(Reference the crosshead assembly shown at the beginning of this
section). If the race is to be replaced it may be heated quickly with a
torch and slipped off the wrist pin.

32
Crankshaft and Gear
Gear Removal and/or Turning
It is necessary to remove a connecting rod by separating the bearing to remove the
main gear (2). The main gear should not be removed unless it is being replaced. The
main gear is bolted to the crankshaft. The gear may have a slight shrink fit to the
crankshaft. If the gear is turned to use the unworn side of the teeth, do not remove the
main gear from the crankshaft. It is necessary to turn the gear and crankshaft together
as a unit. The main gear is not centered in the pump, therefore the pinion shaft and
pinion shaft bearing carriers must also be turned when the main gear and crankshaft
are turned.

PINION AND BEARINGS

Pinion Shaft
The pinion shaft bearings (3) are carrier mounted. This permits the pinion (1) and
bearings to be moved out of the frame to the left or right.

1. Remove the oil lines and bearing carrier bolts (9).

2. Use the jackscrew holes to push the carrier (2) from the pump frame.
3. Support the shaft and remove the bearing carriers.
4. Slide the shaft out of the pump frame.
5. The carrier should remain on its original end of the shaft, because the
pinion bearing (3) inner race and the oil seal race (4) remain on the shaft,
(1) while the bearing outer race and rollers remain in the carrier.
Removal of Pinion with Crankshaft and Gear In Place
The pinion shaft can be removed without removing the crankshaft and gear. Removing
the bearing carriers (2) and bearings (3) allows the pinion shaft (1) to be disengaged
from the gear and taken out of the pump.

33
Removal of Pinion Bearing without Removing Pinion Shaft
A pinion bearing (3) can be replaced without pulling the pinion shaft (1) by removing
the oil lube lines and bearing carriers (2).

1. Support the shaft to prevent it from moving.

2. Use the jackscrew holes in the bearing carriers (2) to jack the bearing
carrier out of the frame.
3. Remove the inner bearing race and seal race with a puller.
Pinion Bearings
1. Use a puller to remove the inner bearing race and seal race (4) .
2. Pull the outer race and rollers from the bearing carrier (2).

34
Assembly (Power End)

General
Refer to the Torque Specification table for proper torque value and tighten all nuts, bolts, and studs to
the specification listed unless specifically noted otherwise. Nut and bolt connections located inside the
pump use lock nuts. Bolts in tapped holes inside the pump are wired for security after the proper torque
is applied.
Pinion Shaft and Bearing
The pinion assembly can be installed with or without the crankshaft and gear in place.

Caution
Never apply direct flame to a bearing. Use either an electric oven
or oil bath to heat the parts.

1. Use either an electric oven or oil bath to heat the parts to 300°F.
2. When heated to the proper temperature, install the pinion bearing (3), inner
races (4), and seal races on the pinion shaft.
3. Place the pinion bearing (3) rollers and outer race into the bearing carrier (2).
This is a slip fit.
4. Install the bearing retainers and bolts (5, 10)
5. Safety wire the retainer bolts.
6. Place the pinion shaft (1) into the pump frame before installing the bearing
carrier assemblies.

35
 7. Carefully slide the bearing carrier assembly and gasket over the pinion shaft
and into the pump frame. Be extremely careful as the bearing carrier
assembly meets the inner race on the pinion shaft.
8. Make sure the oil-line holes in the carrier are lined up to allow the oil lines to
be reinstalled.
9. Press the pinion bearing oil seal (6) into the carrier (2). Use care to prevent
damage to the lip of the pinion shaft oil seal.
10. Install the seal retainer with the gasket and tighten in place.
11. Cover the keyway in the shaft to protect the seal during installation.
Crankshaft and Gear
Gear Mounting
The gear (2) pilot diameter may be a light shrink fit on the crankshaft (1). The gear is
held in place with bolts and locknuts (18, 19).

1. Position the crankshaft (1) vertically with the single eccentric side up. Be
sure to support it underneath the gear-mounting flange.
2. If necessary, evenly heat the gear (2) until it slides over the pilot on the
crankshaft.
3. Use new bolts to install and tighten.
4. Stand at the power end of the pump and look toward the fluid end, and make
sure the gear and pinion are positioned to the right of center.
5. Make sure the gear is installed, so the gear teeth will be mesh correctly with
the pinion.
Connecting Rod and Bearings

Note
Heat the bearings in an electric oven or oil bath to 300°F. Do not
overheat.

The connecting rod bearings (4) are shrink-fitted on the crankshaft (1).Each bearing consists of 3 parts:
outer race and rollers, inner race, and retainer ring.

• Keep the parts of each bearing together as sets.

• Always place the bearing on the shaft so that the roller assembly may be
removed by removing the retainer ring.
• Always place the bearing races against a stop. The stop may be a shoulder or a
set of bolt-on retainers.

36
Connecting Rods
1. Warm the connecting rod (3) to 200°F.
If heating with a torch, do not apply flame directly to the rod. Keep torch
moving to apply uniform heat.
2. Slide the connecting rod bearing (4) down into the rod.
3. Hold the bearing tight against the shoulder until the rod cools.
4. Install the segmented retainers (8) to lock the bearing in place.
5. Tighten the retainer bolts (15).
6. Safety wire the retaining bolts.
Center or Inner Connecting Rod Bearings
The bearing (4) must install against a stop on the crankshaft.

1. Use an electric oven or oil bath to warm the bearing (4) to 200°F.
2. Slide the bearing on the crankshaft with the loose ring leading. The center
bearing must be slipped over the end-bearing journal, because the bearings
are identical in size.
3. Hold the bearing against the stop until it is cool.
4. Measure the distance from the crankshaft shoulder face to the end of the
bearing.
5. Select an appropriate number of shims (14), so the retainers (9) will provide a
0.005-in clamp on the bearing.
6. Install the shims (14) and segmented retainers (9) to lock the bearing in place
7. Tighten the retainer bolts (16).
8. Safety wire the retaining bolts.
Outer Connecting Rod Bearings
All center connecting rods (3) and bearings (4) must be completely installed before the
outer bearing is placed on the crankshaft. Bolt-on retainers (9) are used to form the stop
for the outer bearing.

1. Use an electric oven or oil bath to warm the bearing (4) to 200°F.
2. Slide the bearing on the crankshaft with the loose ring of the outer race
leading.
3. Hold the bearing against the stop until it is cool.
4. Install the segmented retainers (9) to lock the bearing in place
5. Tighten the retainer bolts.
6. Safety wire the retaining bolts.

37
 Wrist Pin Bearing Outer Race and Roller Assembly

Note
Both the connecting rod bearing and wrist pin bearing can be installed
at the same time, if necessary.

1. Use an electric oven or oil bath to warm the bearing (4) to 200°F.
If heating with a torch, Do Not apply directly to the rod. Keep torch moving
to apply uniform heat.
2. Slide the wrist pin bearing (21) into the rod.
3. Make sure the ends of the bearing are flush with the sides of the connecting
rod.
4. Hold in place until cool.
5. There are no bearing retainers to install.
Main Bearings
Installation
These bearings are double row, spherical roller bearings with a tapered bore.

1. Match the tapers and install bearing until straight and snug.
2. Use the bearing retainer and bolts to draw the inner bearing race up onto the
taper until the internal clearance between the outer race and the rollers is .005
in. to .008 in.
3. Use a feeler gauge to check the clearance.
4. Measure the shim gap between the retainer and the end of the crankshaft.
5. Remove the retainer and reinstall with this amount of shims.
6. Tighten the retainer bolts to the proper torque valve.
7. Recheck the internal bearing clearance.
Crankshaft Assembly
1. Place pieces of wood on the lower crosshead guides to protect the guides
from being damaged by the connecting rods during crankshaft assembly
installation.
2. For crankshaft assembly installation, use the same lifting procedure used for
the crankshaft assembly removal.

38
Crosshead Guides
The crosshead guides (2) are bolted into the main frame with clamp bars and bolts (14, 17).

1. Install the guides in the frame without shims, and tighten securely.
2. Use a feeler gage between the top of the crosshead and the top guide at front
and rear of each guide to check the clearance over an installed crosshead
3. Make sure the measurements are uniform.
Operating clearance is a minimum of .014 in. and a maximum of .030 in.
Final Clearance Check
Always check the crosshead clearance after the final crosshead to fluid end alignment.
• Use a long feeler gauge and check the clearance in several places.
Crosshead
1. Pack the wrist pin bearing rollers with grease to insure the rollers stay against
the outer bearing race during wrist pin installation.
2. Place the end of the connecting rod inside the crosshead (1) and align the
bearing with the crosshead hole.
3. Insert the small end of the wrist pin (8) and push it through the crosshead and
wrist pin bearing..
Do not force or drive the wrist pin. The pin is a close fit, but it must not bind
in the bearing.
Wrist Pin Retainer Plate
1. Align the lubrication holes in the wrist retainer plate (11) and the wrist pin (8).
2. Bolt the retainer plate (11) to the installed wrist pin (8) and torque the bolts (9).
3. Rotate the wrist pin-retainer plate assembly to align the holes in the retainer
plate (11) and the crosshead (1). Tighten the retainer plate to crosshead bolts
(10) to 50-ft-lb.
4. Measure the gap between the retainer plate (11) and crosshead (1).
5. Install shims (12) equal to the measured amount less 0.005 in., and torque the
retainer plate to the crosshead bolts (10) to rated torque. (See Torque
Specification table)
Pony Rods
Pony Rod Installation
1. Unbolt and remove the diaphragm plate (5) from the crosshead compartment.

Note
These plates are line bored with the pump frame and must not be
interchanged. The diaphragm plates are marked L, C, and R for left,
center, right.

2. Bolt the pony rod (7) to the crosshead (1) and torque the pony rod bolts (13)
to their proper value.
3. Make sure all the mating surfaces are free of nicks and/or burrs.
4. Slide the diaphragm plate and gasket (5, 6) over the pony rod.
5. Bolt the diaphragm plate to the pump frame.
39
 Seal Stuffing Box
Old Version
1. Place the pony rod oil seals (15) in the stuffing box (3).
2. Make sure the seal on the power end side is facing the power end, and the
seal on the fluid end side is facing the fluid end.
3. Place a lantern ring (16) between the seals.
4. Lock the seals in place with the retaining plates and capscrews.
5. Slide the stuffing box (3) on the pony rod (7).
6. Slide the stuffing box (3) against the diaphragm plate (5).
7. Make sure the grease fitting is located at the top and the pressure-relief
fitting is at the bottom.
8. Bolt it in place and fill with grease.
New Version
1. Bolt the stuffing box (3), without the seal installed, to the diaphragm plate but
do not tighten bolts completely.
2. Slide the alignment tool over the pony rod (7), and use it to properly align the
stuffing box.
3. When the alignment tool can spin freely on the pony rod, tighten the bolts (4)
using a cross tightening method.
4. After tightening the bolts, verify the alignment tool still spins freely on the pony rod.
5. After the stuffing box is aligned, remove the alignment tool.
6. Pack the inside diameter of the seal with grease before sliding it over the
pony rod.
7. Slide the seal (15) over the pony rod and into the stuffing box. The alignment
tool can be used to help push the seal into the stuffing box.
8. Bolt the seal retainer (?) to the stuffing box making certain that the grease
ports line up properly.
9. Pump the box full of grease until it comes out of the seal
Crosshead Alignment

Note
This should be done on an annual basis. A piston rod alignment tool is
required. (See Special Tools section)

For the pistons to run true in the liners, the crosshead (1) must travel in a straight line along the
horizontal centerline of the frame bore. Follow this procedure to check and adjust the crosshead
alignment:

40
 Steel Fastener Torque Specifications (Lubed)
SAE Grade 5 SAE Grade 8 ASTM A193 Grade B7
Fastener Size Fasteners Fasteners Fasteners
Thread
(Fractional- USA Metric USA Metric USA
Series Metric Units
Decimal) Units Units Units Units Units
(N-m)
(ft-lb) (N-m) (ft-lb) (ft-lb) (ft-lb)
1/4 20 UNC 6 9 9 12 7 10
0.250 28 UNF 7 10 10 14 8 11
5/16 18 UNC 13 18 18 25 15 20
0.3125 24 UNF 14 20 20 28 16 22
3/8 16 UNC 23 31 33 44 26 36
.375 24 UNF 26 35 37 50 30 40
7/16 14 UNC 37 50 52 71 42 57
0.4375 20 UNF 41 56 58 79 47 64
1/2 13 UNC 56 76 80 108 64 87
0.500 20 UNF 63 86 90 122 72 98
9/16 12 UNC 81 110 115 156 93 126
0.5625 18 UNF 91 123 128 174 103 140
5/8 11 UNC 112 152 158 215 128 173
0.625 18 UNF 127 172 179 243 145 196
3/4 10 UNC 199 270 281 381 227 308
0.750 16 UNF 222 301 314 425 253 343
7/8 9 UNC 321 435 453 614 366 496
0.875 14 UNF 354 480 500 678 404 547
1 8 UNC 481 652 679 921 549 744
1.000 14 UNF 539 731 762 1034 616 835
1-1/8 7 UNC 600 813 963 1305 778 1054
1.125 8 UN 621 842 997 1352 805 1092
12 UNF 673 912 1079 1463 872 1182
1-1/4 7 UNC 846 1147 1358 1842 1097 1487
1.250 8 UN 873 1184 1401 1900 1132 1534
12 UNF 937 1270 1504 2039 1215 1647
1-3/8 6 UNC 1109 1504 1781 2414 1438 1950
1.375 8 UN 1185 1607 1902 2578 1536 2083
12 UNF 1263 1712 2027 2748 1637 2220
1-1/2 6 UNC 1473 1997 2363 3204 1909 2588
1.500 8 UN 1563 2120 2509 3402 2027 2748
12 UNF 1657 2246 2659 3605 2148 2912
1-3/4
1.750 8 UN 3300 4474
2
2.000 8 UN 5018 6804

Bolt And Cap Screw Markings

B7 Studs
On Head

1. All torque values given are for fasteners lubricated with 30 weight motor oil.
2. All studs used on LTI pumps are Grade B7. Nuts on studs should be torqued to grade B7
specification, even if the nut is Grade 8.
41
Belt Tensioning
Elongation Tensioning Procedure for Banded (Kevlar) Belts

Caution
Exercise care when adjusting (tightening) the Kevlar belts used on
pump drives. Never use a porta power to tighten the belts. These
belts are very strong and have very little stretch. The shafts
supporting the belt sheaves can be damaged if the belts are
tightened too tight.

ALWAYS check sheave alignment when tension is adjusted. Check

alignment when the belts are in a slack condition (no tension). Use a
sheave alignment tool P/N 108-1086, available from LTI. A straight
edge or string across the sheaves on the centerline of the drive
should touch the edge of the sheaves in four (4) places (at the near
edges and the far edges).

New Belts
Using a flexible tape measure, measure the outside circumference of the belt when it is
in a slack condition (no tension). Multiply that number by 1.006. Tension the belt until
the new outside circumference measurement reaches this dimension.

Used Belts
Using a flexible tape measure, measure the outside circumference of the belt when it is
in a slack condition (no tension). Multiply that number by 1.005. Tension the belt until
the new outside circumference measurement reaches this dimension.

42
Special Tools

Special tool needed for LTI pumps, outside of the normal rig tools, include:
• Hydraulic Seat Puller
• Puller Head
• Piston Rod Alignment Tool
• Stuffing Box Alignment Tool
• Laser Sheave Alignment Tool Part Number 108-1086

These tools are available from LTI.

Contact: partsales@letourneautechnolgies.com, or partsales@let-tech.com

Note
The part numbers for these tools depend on the
type of pump. Contact the parts department for the
correct part numbers

43
Troubleshooting
Troubleshooting chart
Problem Cause Solution
• Improper pre-charge or operation Keep discharge dampener pre-charged with nitrogen to
of discharge or suction pulsation 400 to 650 psi.
dampeners:
• Loose or washed ouot valves or • Check for loose seats by pulling up sharply on
valve seats bottom of seat with a jerk hammer.
• Valves cocked in seats: • Examine valves for uneven wear, fluid cuts, and
loose valve inserts.
• Loose piston hubs: • Check piston nut for proper tightness
• Charging pumps output too low: • Charge pressure in the suction manifold should be
between 50 and 70 psi with the mud pump operating.
• Charging pump packing loose or • Hose water over the packing area while running the
worn out permitting air to be charge and mud pumps,
drawn into suction: If knocking stops, adjust or replace packing.
• Restriction in suction line or • Unplug
Knocking
plugged suction line strainer (if
Fluid end
one is used).
• Air or gas in mud: • Examine mud pits for excessive bubbles.
• Check that mud return lines terminate below mud
level.
• Check degassing equipment.
• Loose or worn piston rod clamps • Replace the clamps if the two faces meet metal-to-
metal.
• Tighten the clamps. There should be no relative
movement between the rod and the clamp.
• Discharge cross strainer plugged • Clean the cross strainer.
with trash preventing proper
discharge dampening
• Swollen valve stem guide inserts • Replace the valve stem guide inserts.
causing valves to stick
• Wrist pin too tight • Loosen wrist pin: Remove outer screws in retainer
Knocking plate and bump pin lightly. If pin moves easily in
Power end crosshead, retorque and reshim.
• Upset on crosshead liner. •
Note: • Excessive clearance (over .018 • Reduce clearance
Most pump in.) in crosshead or connecting
knocking rod bearing.
problems are • Excessive clearance between • Reduce clearance.
fluid end crosshead and liner (over .030
related. All in.)
checks upon
the fluid end of
the pump
should be
performed
before
investigating
the power end

44
Troubleshooting
Troubleshooting chart
Problem Cause Solution
• Unbalanced drive sprockets or
sheaves.
• Slack drive chains or belts • Tighten

Vibration • Inadequate pump support. • Resize pump

• Drive chains composed of both •
new and old sections
• Motors not synchronized on a dual • D.C. Motor Drive:
shunt wound, To check – isolate one motor by disconnecting
one drive chain or belt and operating pump with
one motor.
• Insufficient coolant sprayed into • : Check spray manifold nozzles or holes in drilled
liner causing overheating rods for plugging.
• Coolant too hot (over 100°F): • Use a larger coolant sump or heat exchanger or
switch to a non-recirculating clean water system
• Coolant contaminated with trash • Decontaminate or change coolant
and mud.
Rapid Piston • Mud has high concentration of • Check de-sanders and clean mud tanks
And Liner sand or solids: Generally results in
Wear streaked liner bores
• Oil base muds can deteriorate • Check with suppliers and use special pistons and
piston cups and valve disc if aniline valve discs.
point of oil is less than 150°F.
• Corrosive mud attacks liner • The mud pH should be above 8.5. Use premium
liners with corrosive muds. o
• Hydrogen sulfide attacks piston •
cups
• • Paint on the two pilot diameters of the liner:
Liner Remove paint with emery cloth.
Difficult To • Liner bushing “egg-shaped” • Replace liner bushing.
Install In • Burr on piloting diameters inside • Remove burr.
Liner liner bushing.
Bushing • Trash on wear plate • Clean the plate.. The wear plate and liner end
Note: must be clean and dry
Always coat
the liner
piloting
diameters
with drill
collar
compound
before
installation.

45