TRIPLEX MUD PUMPS ~ PARTS BOOK / OPERATING & MAINTENANCE MANUAL B-1100-T | B+1300-T B+1600-T| ! SAFETY FIRST ! Before placing this equipment in operation, certain basic rules of safety should be observed. It should be noted that no safety rules and no amount of safety equipment will moke opercting this equipment sole, unless the operator enforces the rules and proper uses of the eauipment. MACHINE OPERATION 1 2 3. Only responsible persons, trained to do so, should operate this equipment. Be sure all guards end covers are in place and secured before starting the equipment. ‘Moke certain all personnel are clear of the equipment before starting CLEANLINESS AND SERVICE 1 Periodic cleaning of the equipment may reveol potential mechanical trouble spots such os loose or missing bolts, fittings, broken lines, etc. Keep the area cround the equipment clear of loose tools, trash, extraneous matter, etc. Shut the equipment down before servicing or cleaning unless the service work requires the equipment be operating. Allow only an experienced mechanic to se he equipment. Ht a mechanical problem or deficiency is found, correct or report it before continuing operation. Before working under or between components that are suspended by hoists or slings, securely block or crib them. When working in on crea of potential head injury, wear on approved safety helmet, Uae During mest reising operations, maintain slack in the belts between pump drive sheave on compound and pump sheave on rig driven pumps. This will prevent bending or breakage of the compound pump drive shaft from sub-structure movement during mast raising operations. | VEG eiicy if Mony pump parts are heavy or difficult to handle. Plan ae | moves carefully to avoid severe personal injury. Provide fs. supports for disassembled parts. Ra‘This manual hos been prepared with the intention of supplying the user with a valuable service tool. Before plocing the mud pump in service, study this menual thoroughly. Your familiarity with the contents. will prove a great aid in performing any service work on the pump correctly the first time ond os quickly as possible. A general check of all equipment shipped should be made immediately upon delivery by qualified person- nel. Pay particular attention to those parts which were unprotected in shipment and susceptible to damoge. Take into consideration any unsatistoctory conditions thot ore not immediately apparent from surface inspections. Immediately correct any damage prior to installing the equipment. Smell, separately packed items, should be inspected for demage and missing parts. Safely repack these items, ofter inspecting them, until proper installation procedures are token INTRODUCTION SKYTOP BREWSTER COMPANY mud pumps are’ de: signed to allow maximum flexibility in the choice of, + foundgtion material. In the selection of a foundation, consideration must be given to the tremendous ‘amount of torque created by the pump and to the ambient sell conditions. What evar foundation material is selected, assure sufficient access space 10, cal! sump drains, access panels, ond lube oil equip: ment. ‘The SKYTOP BREWSTER COMPANY recommends. the user consult Section J of the "I.A.0.C. MANUAL" for further instructions on the care end meintenance of iplex mud pumps. For the soke of clarification of terminology in service work or paris ordering, use the diogram provided below to differenticte between RIGHT, LEFT, FRONT, ‘ond REAR of the pump. RIGHT FRONT (FLUID END) OOF i REAR (POWER END)DIMENSIONAL ~——___) SPECIFICATIONS DIM. B-1100-T B-1300-T B-1600-T - Us. METRIC us. METRIC U.S. (METRIC A_ | 13-11 9716" 425.6em, 15 - 67/8" ‘474.7om 1s 67/8 a74.7em Bo oS. 3a" [_160.7em ‘5-10 3/4" 179.7om ‘5 - 103/4" 179.7em c C- S316" L 196.1cm T4916 (224.9erm r= 4 ING" 224.9¢m D 74 We | 223.7em e- 37/16 253.2cm, #3716" 252.6em E 5-208 L 156.2em 5-10 5/8" 179.4 Wz" acm | He 4. 07/8" | 124.1em. Tz" V4lem 4 71/2" V4icm Eerste aa | Seiden | POLS em Sg issn | a to Titer} e300 Tsien ed inom | Gar isos | fa | Grams To eee Te ate se am a em uF Bie tees nea item oie Shee ee fee aoe ee tr sen ieee | N | 6-7 201.3em_ 6-10 1/2" 209.6¢em 6 - 101/27" '209..6cmn_ a Bree ee fen [as a Q 36.8cm. 1.4 3/4" 42.5cm. y+ 43/4" A2.Scm te Se eee Fissom ten Tiieg__| spe | ea ‘aan | Tiheee [sa reeee ener ee ree eee ee ee PERFORMANCE LS a B-1100-T B-1300-T B-1600- ‘Mox. Liner Size & Stroke x10" J" x12" 7" x12" ingut HP. Roting 1.100% 14057 T3008 120 37M 100 1205 ‘Mox. Recommended Speed 140 SPM 120 SPM 130 SPA Suction Monifold Test Pressure 1,000 FST. 1,000 P.S.7- TOO PST. Discharge Connection a 3s” = Suction Connection er 10 107 Piston Rod Size =a Bele saa APL 4 Sha APA SKE Valve Size APLAG. ‘APLAT ‘APLAT Gear Rati 4.46421 4.46921 246921 Est. Weight™ 36,750 Lbs. 43,500 Lbs. 29,500 Lbs. 16,670 Kes. 22/450 Kas, 22,450 Kas. “Waghs ine concave oll and denoted dre shee. 1100-T [i [190 | 1 | 10 | 10 | 9 | ssure-Volume ! 1 — lorsepower Chort* | eeeere ae 100 | 1022 | 943 | 965 | 786 | 707 | 629 | i Discharge ae Pressure Rating Ovutput-Gallons Per Minute one (Average) 7 2438 700 | 630 | 600 | 550 | 500 | 450 | so 6 2812 sos | 560 | Si7 | ara | aon | ger | See é +3200 sia | a77 | uo | 403 | g67 | 330 | 299 5% 3928 433 | aor | 36¢ | 338 | 300 | 277 | der 5 2753 357 | aa1 | 306 | 200 | 255 | 229 | 204 a 5000 290 | 268 | 248 | 227 | 207 | 186 | 165 4 5000, ze_| 22 | 195 | 179 | 16 | 146 | 180 B-1300-T | 120 | 0 | wo | 9 | 2 | 7) 6 Pressure-Volume t t Horsepower Chart* | 1300 | 1192 | 1083 ] 975 | 967 | 758 | 650 Sec | gE ae Discharge Output. Une Gollons per Output-Gollons Per Minute 7 | 730 | seo | 00 ] S00 | 450 | ~a20] 300 on s20 | 569 | 517 | 465 | ata | 362 | 310 é 529 | 45 | aa | 397 | 353 | 309 | 265 5% 440 | aor | a70 | 339 | 296 | 259 | 22 5 367 | 3x7 | 30s | 275 | 245 | 21a | 04 aA 8 | 73 | 28 | 223 | 198 | 74 | a9 4 zs _| 76 | 196 | 376 | 157 | 1a | ne B-1600-T Stroker See parker 20 | 110 | 10 | 90 | 00 | 70 | 60 Horsepower Chort Inpot Horsepower | 1600 | 1467 | 1333 | 1200 | 1067 | 903 | 800 ating jenn Discharge Output. Prossure Rating | Gallons p Output-Gallons Per Minute (Average) Revolution 7 ua 6.00 720] @60 | 600 | Sad | 480] a0] 360 on 3980 5 ea | 569 | Siz | 465 | ata | 362 | 310 6 1664 aa 529 | 49s | aut | 397 | 350 | 309 | 265 Su 5000 370 440 | 407 | 70 | 99 | 26 | 259 | 222 5 5000 3108 aer | 337 | 308 | 375 | es | nia | tee a 5000 248 gee | 73 | 246 | 2% | 198) 7a | a9 4 3000 136 za5_|_ me | 196 | 176 | 157_| 137 | via “Bcsed on 90% Mechanical EHicieney and 100% Volumetric EHlelancy,TT TT SHEAVE INSTALLATION (Whore Applicable) Your triplex mud pump is provided with o keyed pinion shalt for power input on either end of the shaft, or both ends. Prior to installing the sheave, clean the pinion shaft and sheave hub bore. Inspect the koyway cond kay for burrs end remove any found. The key may be installed by positioning it in the keyway and lightly tapping it into place using a block of wood and a hommer. Coot the pinion shatt with ¢ clean white lead ‘or heavy grease. The hub and sheave may be installed (03 ¢ unit with the sheave loosely bolted to the hub, or, the hub may be positioned on the shaft and the sheave then bolted securely into position. To oss proper positioning of the hub/sheave assembly on the shaft, mork their position on the shaft before remov- ing them. ‘A means for aligning the pump sheave to the power source sheave, and adjusting drive belt tension, must be furnished. Proper alignment will insure the usable service life of the V-Belts. Due to the inequality of V-Belt length, run the belts ot medium tension. This will llow the’ belts to equalize under operating tension, FLUID END The fluid end should be disassembled following the “FLUID END MAINTENANCE” procedures provided in this manual. All internal parts should be thoroughly cleaned with a non-residual industrial solvent and dryed. Reassemble as described in the "FLUID END. MAINTENANCE” section, SUCTION LINE Emphasis must be placed on providing a correctly sized and placed suction line. The suction connection provided is a flonge (B-1100-7) or 10" pipe (B-1900-T and 8-1600-T) for welding directly to the customer's suction line. This weld MUST BE AIR TIGHT. The suction line between the pump ond mud tonk should be as short as possible. When reducing suction ling size, use only eccentric reducers to prevent ait pockets in the line. ‘At least one section of suction line should be hese. This will ceduce transfer of pump vibration and reduce wear on related components. AA strainer should be installed in the suction line to prevent debris from being drawn into the fluid end. It must be checked frequently and cleaned whenever necossary. When installing the suction manifold, insure that the mating faces of the flvid end and manifold are smooth ‘and free of defects. Inspect the "O” Ring channel for smoothness and the "O" Ring for cuts or distortion. INSTALLATION Install the copscrews finger tight on all studs before moking-up tight using the triangulation method of ‘each flange. DISCHARGE MANIFOLD The discharge manifold is provided with o 4" - A.P.L 15000 tb. Flange connection (8-1100-1) or aS" + A.PLL '5000 Ib. flange connection (8-1300-T and 8-1600-1) The manifold is attached to the steel fluid end sections with four heavy hex nuts for each fluid end section ‘An “O" Ring Is used to seal the connection between the discharge manifold ond fluid end sections. When installing the discharge monifold, insure that the mating faces of the fluid end and menifold ore smooth and free of dofects. Inspect the "O” Ring for cuts or distortion. Install the nuts finger tight on all studs before moking-up tight using the triangulation method at each flange. Use make-up torque fer grade: @ bolts shown on page 14. RELIEF VALVE Check the roliet valve to verify the proper setting. This setting should be no greater than 30% above 1h working pressure of the liner size installed in the pump, NEVER operate the pump without @ relief valve, doing so endongers the lives of the craw ond seriously damage the fluid ond in the event of a pressure surge or line blockage. PRE-START-UP CHECKLIST Betore placing the pump in operation for any reason: —Remove all inspection doors and check for con- teminetion and obstructive objects. Lubricate the pump as outlined in the “Lubrico- tion” section of this manual and on the specifice: tion plote on the pump frame. —Check the tightness of all pump, fluid ond, and ‘anchoring bolts. Rotate the pump by hand to assure free move- ‘ment. —Vority the correct rotation of the pinion shaft. This Is to assure proper lubrication of the power ‘end. The correct rotation is indicated by the top of the pinion shaft turning away from the fluid end, —PRIME THE FLUID END by removing the discharge valve and filling each cylinder with water. This is must os it lubricates the pistons ond liners. Aitar the pump has been in operation for one day, and ‘again after ten days, all nuts on the fluid end should be checked for tightness.eae LUBRI POWER END (Ref. Pgs. 25 & 26) SKYTOP BREWSTER COMPANY triplex mud pumps are internally lubricated by a pressurized lubrication sys~ tom. In this system filtered oll is pumped, by on internelly mounted oil pump, to the crankshott main earings, pinion shoft bearings, and crosshead assemblies. Apressure gauge (46), located on the front woll of the pump frome, measures cil prossure in the lubrication lines. The pressure will fluctuate occording to the pump operating speed. Should any radical changes in pressure occur the pump should be shutdown and the cause of the chonge investigated. Never operate the pump with less than 5 P. 0, The relief valve fon the lube pump should be set at 40 P.S.1. 11s importent that the proper crankcase oil level be maintained. The oil level may be checked with 1 pump idle by following the prescribed procedures. Allow the pump to ramain idle for a five minute period before checking the idle oil level. This will allow the cil to equalize ond give © “Full” reading at the top mark of the dipstick. Oil, as needed, may be added through the inspection cover on the top of the power end. ‘Once a weak, remove a settling chamber drain plug to drain any accumulation of water. The oll should be routinely changed ofter six months (oF 2,000 hours of operation, or if the oil has become overly contaminated. Repiace the oil with approved lubricont. At each oil change, remove the breather cop ond clean or replace the copper wool filter. Clean the magnets on both sump droin plugs. Remove the crosshead covers and settling chamber drain plugs. Clean the settling chamber beneath the crosshead of all sludge and debris. To obtain an oil sample, or to drain the sump, © magnet droin plug is provided ot the base of both dipstick sheaths on the sides of the power ond (see Fig. A) A lubricont filter serean is located in the power end sump adjacent tothe oil pump. This screen should ‘leaned on o regular bosis ori o significant pressure drop Is note CCROSSHERD covER PINION SHAFT INSPECTION COVER seTTuINs Geaweer > ae pipstick~/, ‘SUMP ORIN ICATION 7 PISTONS and RODS The pistons and liners, ore cooled and lubricated by either a mechanical or electrical pump system. Both systems direct clean woter onto the pistons and liners ino reguloted flow, adjusted by « valve locoted o¢- jacent to the stuffing box. Water running off accumy- lates in a compartmentalized sump, located below the piston rod, where it is recirculated by the lube pump system. This sump collects effluent ond solid woste which might otherwise be recirculated through the lubrication system. The sump has dreins on both sides of the pump to allow flushing out any residue and should be flushed ot each oil change (Ret. Pgs. 27-30) Keep the flow of woter only in quantities needed to keep the piston rubber cool and lubricated, ond the liner well washed. Clean water should be used. LUBRICANT CAPACITIES = B.1100-T —_B-1300-T Crankease Oil —95Gal,—_165Gal. 200Liters 625 Liters Piston Lube TOGal. _80Gel. 80a. (Clear worer) 26S Liters 303Liters 30SLiters RECOMMENDED CRANKCASE LUBRICANT GRADES Ambient Temperature: +90°F, To +125°F, Use 0°C. To — 52°C AGMA 6 EP Ambient Temperature 20°F. To + 40°F. Use 80°C. To + 5°C. AGMA #4 EP ecomiesrion pate AA exo Ye 8 scans ma MaNFOLDMAINTENANCE To remove: 1, Position the crosshead in the maximum back- stroke position. 2. Loosen bolts (21) end nuts (22) and remove the piston rod following the instructions in the fluid ‘end maintenance section, 3. Remove the baffle disc (24). 4, Remove the cover plate (8), crosshead exten: packing set (18), packing sleeve (17), and "0" Ring (20) 5, The stuffing box (7) and stuffing box plate (26) may now be removed. The crosshead extension (6) con be token out by removing the six allen head copscrews (14). 6. Center the crosshead in the door opening. To re. move the wrist pin (4), remove four capscrows (13) end place two of them in the jackholes pro- vided in the wrist pin retainar plate (5). Apply ‘equal torque to the capscrews until the pin brocks loose. Mark the pin to identify which crosshead it mates and set it aside. 7. Place @ block of hardwood under the connecting rod to prevent damaging the lower crosshead guide. While supporting the connecting rod, rotate the pump to pull the rod out of the cross. head. Ease the rod onto the hardwood block when it clears the crossheod. 8. The crosshead may now be slid forward out of the crosshead compartment ond hoisted out of the pump frame through the topside openings. To install: 1. Reploce the crosshead into the frame. A little lub- ricant applied to the lower guide will help in 2. Clean the inner rece of the connecti ith 0 non-residual industrial solvent and inspect It for nicks and burrs. Insert the rod and center it in the crosshead. Place the wrist pin through the crosshead and wrist pin bearing. Be coreful not to damage the bearing. Set the wrist pin by placing a block of hardwood against the exposed end, ond striking it with © hammer until itis seoted. 3, Replace the retoiner plote ond bolt it securely into place. Tighten the capscrews with uniform torque using the triengulotion method, Replace the sotety wir 4, Replace the crosshead extension and copscrews, tightening the copscrews using the triangulation method. Replace the safety wire. Replace the stuffing box plate and gaskets, and the stuffing box and gosket (25). ‘Apply @ cost of grease to the crosshead extension tnd slide on new packing set and packing sleeve. Examine the “O" Rings for cuts or wear and replace if domaged. Install caver plate and secure with capscrews. 6. Slide battle disc into position and reconnect cross: head extension to the piston rod with piston rod clamp. With the guides and crosshead installed, measure the clearance between the top surface of the crosshead CROSSHEAD GUIDES (Ret. Pgs. 21.8 22) To remove the upper ond lower crosshead guides, remove the copscrews (12) being coreful to support the upper guide to prevent its falling. During normal pump operation, the lower guide will tcke the brunt of the wear imposed by the motion of the crosshead. In some instances, the upper ond lower guides moy be reversed, but only if the existing upper guide has © smooth, unblemished surface, if both guides are worn or damaged, they should be replaced with new units, Install the crosshead guide copscrews with "Locktite.” The horizontal conter lines of the crossheads must match the center lines of the fluid end frame bores for the pistons to run true to the liners. To check elignment: Shim crossheod guides to center the end of the piston rod in the pump frame front plate bore. Using © dial indicator with 6 flot tip against the top of extension rod, slide the crosshead to determine if the rod is running horizontally or at an angle. A shim should be placed between the crosshead and upper guide at the rear of the crosshead te prevent tho crosshead from tipping ond giving erroneous readings. Maximum allowable deviation from horizontal is 002” measured x inches of crosshood travel. Shim as required cllowable deviation. Check to see if piston centered in pump frome front plate bore, if not, repeat the procedure until all requirements are met. After crosshead is properly aligned, remove the shim between the crosshead and the upper guide. Failure to remove this shim will result in damage to the pump. Hf shimming is required, bear in mind thet the minimum cleerance between the top of the crosshead, ‘and upper guide is .010." The shimming material should be steel shim stock ond the strips should be long enough to completely cross the guide.OPERATION SKYTOP BREWSTER COMPANY triplex mud pumps are quality built machines, and o good maintenance program will assure many years of dependable servi may prevent personal FLUID END 1, SUCTION LINE—The slush pump transmits @ con- siderable amount of vibration through the suction ling. This vibration may eventually loosen the suc- tion fine flange connections. Always keep these jury or expensive down time. 2. CYLINDER LINERS AND SEALS—The scrubbing ection of the piston rubber and the obrasiveness of the drilling fluid will eventually wear the liner ‘ut. Damaged pecking may cause fluid end wash- outs. Each cylinder head flange has o woop hole at the bottom centerline. A flow from this hole indicates cylinder head looseness or demaged cylinder hecd gasket. If a leak is noticed, tighten the cy- linder head until the leak stops. f the lock persists then the pump must be shutdown and the cause identified. When replacing the liners, exercise core in han- dling them to avoid damaging the sealing surface: of the liner. If the liners are to be stored for an extended period, coat them with grease to Prevent corrosion, Always replace cylinder head gaskets and liner seals when replacing the liners. When tightening down on the gaskets and seals, use only as much pressure as is nacessary to prevent leakage. Over-tightoning the seals will only reduce their service life. 9. VALVES, SEATS, AND GUIDES—Worn volv seats, and guides will seriously impair the off tency of the pump. Worn valve guides do not allow proper seating of the valve, be aware of their condition and replace as necessary. Do not mix worn valves or seats with new valves or seats. Replace the sealing element on the valve before it lacks to extend sect Scheduled inspections of the following points, during pump operation, 4. VALVE POT COVERS AND GASKETS—Look for looking fluid around the valve pot covers. If leak: age is detected, tighten down on the leaking stops. If the leak persists then the gosket must be replaced. 5. STUDS—Replace any stripped or damaged studs ‘at first opportunity. The load which the damaged stud should be bearing is transferred to those ad- joining studs which could cause their premature foilure. Refer to torque value chart for proper torques, 6 PRESSURE RELIEF VALVE—Chack the valve to ‘assure proper operation and that it is properly set. 7. PULSATION DAMPENER—Periodically check the tightness of all bolts and check the charge on the bladder. POWER END 1, PISTON ROD LUBE OIL PIPING—Orilling flvid and sediment deposits must be flushed from the com- Portmentalized lube cil sump. Keep the oil clean to lessen the wear on the lub oil pump, piston, and liner. 2, CROSSHEAD EXTENSION—Keep tho rod made-up tight ot all times to the crosshead body. Keep the piston rod clamp tight at all times and replace when it fails to secure the crosshead extension ‘and piston rod tightly. 3. POWER END STUFFING BOX—The stuffing box prevents drilling fluid from entering the power fend and the power end lubricant from leaking ‘out. The packing should only be tightened enough to prevent leakage. Over-tightening will only ‘accelerate woar on the packing, MAINTENANCE PINION SHAFT (Ret. Pgs. 19.8 20) The cronkshaft must be removed before the pinion shaft can be removed or installed. The pinion shaft assembly may be removed from either side of the pump frome if the proper hoisting equipment Is ovailoble at the well site. Because of the ‘awkwardness of handling the weight of the shaft the close quarters of the pump frame, CAUTION is ‘advised to prevent personal injury and damage to the pump. To remove: 1. Support the shaft with timbers to toke the shaft weight off of the bearings. 2. Disconnect the oil lines at both ends of shaft. 9. Opposite the pump side through which the shaftMAINTENANCE will be pulled, remove copscrews (22) and pinion bearing retainer (26) by using the jacking holes provided. Heat the spacer (27) carefully by torch ond remove. Be careful not to burn the shaft 4. On the pump side through which the shaft will be pulled, remove the copscrews, retainer, and spocer as described in paragraph 3. Remove cap- screws (20) on the bearing carrier (25) ond use ‘two of them in the jack holes to remove the cartier. The shalt moy now be pulled for service. To install pinion sheft, reverse removal procedure shown above. 1, Cleon the contact surfoces of the bearing carrier (25] and retainer (26) ond install new gaskets (95, 36) 2. The corrier ond retainer have "Top" cast on them, Insure thot these pieces ore installed with “Top” vp. 3. Before installing the retainer ond seats (28), apply € light coat of lubricant to the spacer (27) to ease sliding the seals into position. 4, Tighten copscrews (30, 92) by the triangulation method end replace safety wires, Replace lube oil lines. CRANKSHAFT (Ret. Pgs. 17.8 18) To remove the crankshaft from the pump chassis: 1. Determine, by looking at the center crossheod, from which side of the pump the center crosshead wrist pin will be removed. Remove the wrist pin from the outside crosshead (on the side the center crosshead wrist pin will be removed) using the jecking holes provided. Follow the instructions under “Crosshood Assombly” for wrist pin ro- movol. Slowly back the connecting rod out of the outside. crosshead allowing it to rest on o hardwood block placed on the lower crossheed guide. These blocks ore importont in that they protect the ‘guides from scarring by the rods. Push the outer crosshead forword to gain access to the center crosshead, Follow the above procedures 10 remove the center crosshead and other outer crossheod. 2, Disconnect the lube oil pipes from the main beor- ing housings ond remove the housings. Remove coil pump to avoid bending oil pump shoft during, crankshaft removal. (Ref. pg. 25 & 26). 3. Slings should be positioned on the crankshaft so nr ee eet TIT Tt re thot it will remoin level while being hoisted. Litt ing holes ore provided in one eccentric and the gear flonge. The connecting rods should be sup- ported with slings to prevent their damaging the crossheod guides during removal 4, Raise the crankshatt slightly to take the weight off the main bearing carriers. Rotate the carriers 90° so that the flot surface of carrier is verical and fecing the rear of the pump. Ease the shatt slowly out of the frome ond rest it on a mat of wood planking to protect the gear teeth. Support the assembly securely, aL Mony pump ports are heavy or difficult 10 hondle. Plan lifts ond moves carefully to ovoid severe personal injury. Provide safe supports for disossembled ports. The crankshaft assembly must be removed to install few main and connecting rod bearings. To remove main bearings: 1. Remove the bearing retainer and shims carefully setting them cside as to differenticte between which sets go on the pump right or left side. 2. With an appropriate puller, remove the main bearings. If the bearings are to be re-installed, protect them from contamination and note from which side of the pump they come, DO NOT r verse the sides from which the bearings were originally installed. ALWAYS replace the bearings in their original position To install main bearings: 1. Clean the inside diometer of the bearing race ond the cronksheft bearing seots with ¢ non-residval industrial solvent. 2. Seat the beoring hand tight onto the shaft. With o depth micrometer, meosure the distonce from the ‘end of the bearing to the end of the shaft. 3. From the dimension gained in the previous step. subtract .072" (B-1100-T) or .086" (B-1300-T ond B-1600-1). This will determine the required shim thickness. 4. Install the shims ond the bearing retciner, and then bolt the ossembly down tight. With the bearing installed on the crankshaft, check the diamet ‘ical clearonce at the bottom of the bearing. The tolerance should be .0035” to .0075". Replace the safety wires on the retainer capscrews. CONNECTING ROD BEARING To remove or install bearings, the crankshaft must be removed trom the pump frame, ALWAYS install center connecting rod FIRST during re-assombly. To remove: 1, On the center and outer connecting reds remove capscrews (15) and bearing retcinors (11). Cara- fully slide the outer rods off the crankshatt ond set aside, Do not confuse from which side the rods were removed. 2. The bearing inner races from the outside rods must be removed carefully by heating before the center rod can be removed. Exercise caution in doing this to prevent burning the bearing seats on the crankshaft. Once this is accompli the canter rod moy be removed by following the same instructions os the outer rods. 3. Remove the center rod inner bearing race by care- fully heating and then sliding it off it’s seat and over the outer rod bearing seat. To install: 1, Clean the inside diameter of the connecting rod end the beoring seat on the crankshaft with a non-residval industrial solvent. Carefully heat the rod with @ torch until the insi diameter is hot to the touch. 3, Slide the bearing outer race in until it rests evenly ‘on the shoulder. Install the bearing retainer (10) ‘and copscrews (15). Carefully heat the bearing inner race with a torch until itis hot to the touch, Keep the torch moving to prevent localized heating. Slide the inner race cover the outer bearing seat and onto the center seat until it rests evenly egainst the shoulder. 5. Alter the inner and outer races heve cooled and set, carefully slide the rod onto the inner race. 6. Secure the rod to the crankshaft by installing thi bearing retainer (11) and copscraws (15). Replace all safety wires, 7. On the outer connecting rod bearings, install the bearing retainer (11) ond capscrews (15) and tighten. These retainers act os shoulders for the stall the bearings os directed MAINTENANCE CROSSHEAD BEARING (Ref. Pgs. 21 & 22) To ramove the bearing from the connecting rod, core- fully drive it out using a hammer and brass drift, Be careful not to damage the bearing bore. Before installing o new beoring in the rod, inspect the bore for nicks or burrs, and clean the bore with @ non-residual industrial solvent. Do not remove the packing lubricant from a new bearing unless it is soiled. Heat the eye of the rod to 300°F. with @ torch moving the torch constantly to prevent localized heat ing. Use a "temple stik” to determine rod tempera: ture. Position the bearing ia the bore so that the ends of the bearing are flush with the sides of the connect ing rod. Hold the bearing in position until the rod cools. DO NOT USE WATER TO COOL THE ROD. CRANKSHAFT INSTALLATION 1. Clean the bearing seats in the frame with @ non: residual industrial solvent and inspect for any sur- foce nicks or burrs. Apply a light lubricant. 2. Hoist the cranksheft assembly, support the rods with straps. Rotate the bearing carriers so that the flot surface of each is vertical and facing the rear of the pump. This provides the necessary clearance for the carrier to siide into the sect. 3. Slowly, and very carefully, lower the assembly into the frame until the rods can be inserted into. their respective crossheads, Be certain that the lower crosshead guides are protected with hard- wood blocks or similar protective bumper. Guide the bearing carriers into the seats, The bearings must not bind on the seats, as this might damage the carrier or sect surfaces. 4. Install the main bearing housings, which ore. stomped "left" ond “right” on the top side of each These housings must not be interchanged. Re place the safety wires, ond reconnect lube oil fines. 5. With the crankshaft instolled and the bearing re- tainers secured in their respective positions, check the bearing rollers to assure that each row of rollers in each bearing is equally loaded. The ‘some number of bearing rollers should be tight on both sides of each bearing. 6. Replace the oil pump and clean or replace the lubricant filter. (Ref. pg. 25 & 26). CROSSHEAD ASSEMBLY (Ref. Pgs. 21 & 22) The left ond right crossheads must be disconnected from their connecting rods ond pushed forward to goin access to the center crosshead.MAINTENANCE ) FLUID END \ The SKYTOP BREWSTER COMPANY fluid end consists of three forged steel fluid end sections (with valve ond liners), nee dischorge manifold, and 0 suction manifold either one inlet or alternate two inlet FLUID END BLOCKS (Rot. Pgs. 23 & 24) sure the liner lip mokes flush contact with the fluid ond block shoulder. The fluid end blocks make-up metol-te-metal to the power end with heavy hax nuts and studs. The blocks 3. Install liner retainer collar (20) and liner ring (19) are aligned with the stub rod centerlines by 0 The copscrews on the retainer collar should not be shouldered recess in the power end front plate for over-tightened resulting in collar distortion. After : ech block. the pump is operational these capscrews should ! be tightened only enough to prevent movement of ; The mating surfaces on the fluid end blocks ond the the liner power end frome must be clean and free of ony : defects to insure on aligned installation. Tighten the i hhex outs using the triongulation method ond the ‘applicable torque value shown on page 14. VALVES AND SEATS (Ref. Pgs. 23.8 24) i To remove: ! LINERS i 1, Remove valve cover lock (4), valve pot cover (8), i To remove: cylinder head fock (5), end eylinder head (9). | 1, After removing suction valves (see "VALVES AND 2. Remove the lower valve guide (10), with attached SEATS" section) loosen and remove copscraws lower guide bushing keepar (11) and bushing (35), {(82), liner ring (19), and liner retainer collar (20) by tipping the top of the valve guide back and re: | fe cloarance forthe top of 2. Pull liner out through the fluid ond block and re- tem to clear the guide bushing 7 move liner gaskat (27). Liners that are te be used 1ove the suction ond discharge valves and ‘again should be coated with oil to protect them springs egainst rust, 3, To remove the valve seats, it is recommended To install that a mechanical wedge or hydraulic valve sect puller be used. Using a torch to remo 1. Thoroughly clean the liner inside, and out, remov- seats is not recommended because of the poten: ing any preservatives. Clean the machined sur- tial of burning the velve seat tap i faces ofthe liner bore ond inspect for nicks. burrs, , or washouts fa mechanical or hydraulic puller is employed, 0 : stem extension ossombly is necessary to pull the 2. Apply o light coat of lubricant to the outer suction valve seat. The discharge valve seats must diometer of the liner and install now liner gasket be pulled before the suction valve seats. (Ref. Fig (27). Cerotully side the liner inte position making 8) MAIN STEM joes nur UPPER ADAPTOR a mate : “7 TOP WEDGE Kock 7 weoet Yi som exten Z PLATE s0TTOM WEDGE aLocK g i iH sus stem 27004 HEAD $ Putter HEAD sear Fig. B HYDRAULIC PULLERieee MAINTENANCE Mechenical Wedge—Place the too! stem with ‘upper odapter plate and stem extension through discharge sect cross-arms. Loy bottom wedge — block over the stem, then wedge, top wé ge block, and nut. When placing wedge, insure that the flange studs ore protected with cloth packing, Attach puller head, sub-stem and lower edopter plate to stem extension ond suction seot cross- ‘arm and take up any slack in the assembly. Tight- ‘en main stem nut by altornat ly. striking the wedge with a sledge end forcefully tightening the ut. The suction oat will pull fr ‘and may be removed through the cylinder head flange. The discharge sect moy be pulled by delet. ing the stem extension assembly and attaching the puller head directly to the main stem. Hydra end stem os @ mechoni ie Pullers—Use the some type puller head | wedge but 0 hydraulic jack is substituted for the wedge. When using this type puller make sure itis secured to the fluid end 10 provent its falling when the seat breaks loose. 4. Alter the sects are pulled thoroughly wash the seat decks and surrounding surfaces. Inspect the tapers for cracks, woshcuts, or roughness and air o$ necessary. Clean the tapers wit residual industrial solvent and protect them from ny contor To install: ( 1. Remove ony rust valve seat with Place the seat in the toy hand. The sect should 1otion until new seots ore installed. ibitor coating from the new non-residval industrial solvent. ond press firmly by k in the taper firmly with even contact between taper and seat around their circumference, Hf even contact is not made the seat should be cerefully removed and the cause identified and corrected. 2. With the sect firmly placed in the taper, set it by placing on old valve on the sect ond striking tho Upper stem with e sledge hammer. The hammer should bounce free if the seat set properly. DO NOT rely on pump pressure to s00l the sect 10 taper, doing so may couse washeuts on toper and sect. 3. Install new suction valve and spring. Examine lower valve guide bushing for damage or wear. Weor should not exceed 1/16" clearance around valve stom. 4. Replace lower valve guide and bushing keeper by tipping the top of the valve guide back and slip over valve stem. Lightly grease new cylinder head gosket (26) and install. Replace cylinder head, threoded flange (with weep hole at bottom), and ~ cylinder head lock. Inspect upper valve guide bushing for defects ond wear as directed in step 3 above. Install new volve. Apply a light coat of grease to valve pot gasket and install. Replace threaded flange. valve Pot cover, and vaive cover lock. PISTONS and RODS (Ref. Pgs. 21-24) The piston and rod assemblies may be removed through the fluid end biocks by removing the cylinder head locks, cylinder heads, and valves. Loosen bolts, ‘ond nuts (21, 22) on the piston rod clamps ond remove the clamps. The rods with pistons may now be slid out through the fluid end block. To remove the piston body and rubber loosen and remove the splined nut using the splined wrench. Inspect the piston sect ond flange on the rod for ‘excessive weer or washeut damage. Replace os necessary. To instali new piston body and rubber: 1. Clean threads, rod end, and rod flange thoroughly ‘ond epply c light coat of grease to these areas. 2. Lightly grease piston "O” Ring and place in piston 10" Ring groove, Seat piston squarely agcins rod lange. 3. Replace splined nut ond tighten as follows: Piston with 1-1/2" or 1-5/8" holo—one man's weight on3' splined wranch-cheoter combination, iston with 1" splined wrench, hole—one mon's weight on 18” To Instoll new piston rubber only: 1, Remove old piston rubber by driving loose th snap ring with a 60 penny nail. The ring will peel off in a clockwise direction. Remove the piston re- tainer plate and carefully pry the old rubber off 2. Clean the piston seot of all coked mud, rust, or piston fabric. Inspect piston body for wear or weshcut damage, 3. Firmly push new piston rubber into place and in- stall new piston retoiner plate. Install new snop ring with short firm strokes of o hammer working in @ counter-clockwise direction. Once the snap ring is in place, check it by strikin fence again with a hommer to assure i well. ton and rod in the pump, grease the piston to ease instollation. If the piston rubber is notural rubber do not use grease, but instead, use solution of detergent used in drilling muds, or @ rig ‘washing compound. It may become necessary fo use & timber and sledge hammer to drive the assembly into the liner after corefully storting the back lip in the liner. Replace piston rod clamp and tighten.meme ere Tt te MAINTENANCE ) PULSATION DAMPENER CHARGING INSTRUCTIONS 1. Remove the pulsation dompener gauge cover located at the top of the dampener. 2. Connect the charging hose to the dampener charging valve and to the nitrogen cylinder valve. 3. Open the dampener valve completely. 4, Open the nitrogen cylinder valve slowly, using this valve fo regulate the flow to the dampener. 5. When the desired pressure in the dampener hos been reached, close the nitrogen cylinder valve. 6. Close the dampener valve. 7. Remove the charging hose from the dampener cand the cylinder and replace the gauge cov MUD PUMP DAMBENER Baessuae / NITROGEN, GAUGE SHARGING pameenesl vane BHARGING Rose DAMPENER STORAGE and PRESERVATION Prior to storing your mud pump for a lengthy time, certain precautionary measures should be taken to cessure the well-being of the pump and its components. 1. Drain the fluid end. 2. Unscrew the valve cover locks and remove the valve pot covars, springs, and valves. Thoroughly clean each component and coat with rust inhi 3. Apply rust inhibitor to all interior ports ond sur- faces of the cylinder and valve areas after the fluid end has been drained, 4. Drain and clean the piston rod lube sump. Coat ‘expoted rods and cressheed extension rods with rust inhibitor, 5. Hang desiccant bags in each valva pot cover and in each liner cage and reassemble the fluid end components. Seal the suction and discharge the fluid end, Release the nitrogen pressure in the pulsetion dampener and remove it if the pump is to be red. Take apart and clean the dampenar ing to the manufacturer's instructions. ly crate and tag the dampener to assure sofe transport. Drain the power end main sump of all lubricant. Remove the crankcase and crosshead covers and clean the interior surfaces. Coat all surfaces with rust inhibitor and hang several desiccant bags Replace the crankcase and crosshead covers, and then seol. For storage in freezing temperatures, the above procedures will prevent any freeze damage to the fluid end.Main BEARING Nousine RECOMMENDED FORGUE=Fe-Lbe, Ory L 1109-7 so00 + 200 Bao see0 = seo B-ieoe-7 10500 = 300 SAFETY WIRE SAFETY WIRE MAIN BEARING HOUSING 16-20 Gouge—Ensure thot wire is “pull TORQUE VALUES ing both copsrews ino tightening MAKE-UP TORQUE VALUES FT. LBS. Bor SAE SAE SAE KD GRADE GRADE GRADE GRADE Z 5 7 8 qe BOLT SIZE DRY LUBE | DRY LUBE DRY LUBE S/16-18NC 1617 1248 20-21 15.6 23.25 17.18 ~ 1_snezne 18:19 13.4 22.24 17.8 23.25 19.20 14 B/A-16NC 28.20 2123 37-40 19:20 4245 33-35 3/8-24NF 39.35 2.25 42-45 28-30 47-50 33.35 7/16-14NC 47-50 3335 56-60 42-45 65-70 51-58 7/16-20NE 51.55 37-40 65.70 47-50 74:80 56-60 V/2-19NC 70:75 51-55 88-95 65-70 102-110 74-80 1/2-20NE 64.90 61-65 93-100 74.90 1125120 84.90 9/16:12NC 102-110 7489 126-135 93-100 140-150 102-110 9/16-18NF 112.120 84.90 140.150 102-110 158.170 121-130 5/6-1INC 140-150 102-110 17-190 130-140 205-220 158.170 S/O18NF___|__ 188-170 121.180 195.210 149-160 223.240 167-180 3/4-10NC 7242-260 186-200 298-320 228-240 353-380 260-280 3/4: 16NE 219-300 208.220 395-360 260-280 391-420 298-920 7/8: 9NC 400-430 256-320 484-520 372-400 ‘358-600 426-460 1/8-\ANE 437-470 326.350 539-580, 409.440 614-660 468-500 1. 6NC 395-640 1446-480 744-800 "558-600 1837-900 682-480 1 s12NF 651.700 498-530 800.860 614-660 990-1000 1178. INC 744-800 58-600 | 1042-1120 71-840 | 1190-1260 1-1/8-12NF 810-200 614-660 | 11721260 974-940 | 1399-1440 1904-1080 Vlas INC 1042-1120 78}-840 | 1469-1580 1023-1100 | 1699-1620 1265-1360 iia enc | 1098-1180 e19-ae0 | 1583-1670 11261210) 177-1910 1390-1490 1-1/4-12NE- 1153-1240 ese920__| 1637-1760 1228-1320 _| 1860-2000 1395-1500 7 1-3/8 6NC 1388-1460 1023-1100 1984-2080 1451-1560, 2213-2380 1655-1780, 1-9/6-12NE 1562-1680 1172-1260 _| 2219-2980 1655-1700 _|_2590-2720 1897-2040 1-1/2. 6NC Te0u-1940 1088-1480 | 2585-7780 934-2080 | 2959-3160 72195.2360 72. 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