WHEATLEY operators manual For HP-160 & HP-250 Series Plunger PumpsINTRODUCTION INTRODUCTION Wheatley pumps are manufactured ia accordance with the highese seandards demanded by the petroleum industry. Proper maintenance and care will prolong the period of satisfactory service, and reduce costs. ‘These instructions were wi care, operation, and maintenance of your pump. When trouble arises outside the scope of chis manual, ‘our Engincering Department and all other factory facilities are ready to help you, Feel free co contact us For assistance, ft promore the To fof the problems and solutions which occur in the field, We request that you send to us short reports of your experiences, Include che purnp figures and serial improve our products, we must be informed ‘numbers, the operating conditions, the problems, and the solution, if any, and forward to Wheatley , ATTENTION: Engineering Department, P. 0. Box 3249, Tulsa, Oklahoma 74101. Your help will be greatly appreciated SERVICE Wheatley fs distributors throughout — the United States who have servicemen available in cease of emergency or a major overhaul. Most of these distributors have parts available and can give you the necessary help in service work, We prefer that all service be handled through an authorined distibut however, in extreme emergencies, Wheatley dispatch a serviceman. This normally will require a 24-hour notice.HP-160 SERIES & HP-250 SERIES PLUNGER PUMP INSTALLATION INSTRUCTION PROPER INSTALLATION Proper installation is of prime importance, The ‘uid lifting capabilities oF @ reciprocating pump are limited. 1 is necessary c@ flood the pump suction, with uid as a minimum requirement for satisfac- tory operation. Pumps with “L” or "H fluid end will operate with a floaded suction, But pumps with "M" fluid end running above 360 RPM may require 4-20 Psi suction charge pressure. Refer to perform ‘The Engineering Department of Wheatley Company is available for consultation on your pumping probe lems. Doubtful conditions should be checked with the Engineering Department prior to installation of the unit. The requirements vary with different liquids. The general requirement is a flooded suetion [eight ounces), minimum positive pressure, or one foot of head. THE SUCTION LINE ‘The Suction Line size must equal (or exceed) the size of the pump suction manifold connection. It is, desirable to use flexible hose rather than piping. The number of ells or turns should be kept to an absolute minimum, An ideal installation would have none at all. if ells are necessary, they should be installed no closer than five (5) feet to the pump inlet, and no two ells should be closer together than three (3) feet. All valves in the suction line must be the fullopening type. 45° ells are greatly preferred, rather than 90° ells; or, 45° branch lateral plus 45° ell are better than 90° ell DISCHARGE PIPING Discharge piping should extend at least five (5) feet from the pump before any turns or ells ste installed. To eliminate line stesses on the pump, it is again recommended that high pressure flexible hose be installed for the frst five (5) feet. Any ells used should be 45° type rather than 90°. Again, 445° branch lateral phus 45° elbow is preferable to 3 single 90°, el RELIEF VALVES Relief valves protect pumps from failure due to excess pressure and must be installed in the dix charge piping. If desited, relief valve and bypass piping can be installed at the factory on new units At minimum additional cost, Operation without a properly set relief valve (setting to correspond to size plunger used) is dangerous and we will not be sesponsible for toss of life or property, nor held liable for damage, nor will we accept responsibility for premature failure of any parts resulting from lack of a good relief valve, correctly set. ‘This pump is a sturdily built, precisely manufac- tured, and creatively engineered unit. If properly installed and given careful preventive maintenance, maximum service at the lowest possible cost is attained. Make sure suction and discharge hookups are proper, then read the pages of periodic mainten- ance. Then start the pump. TO START THE PUMP To start the pump, roll pump over once by hand. ‘Then open the suction line valve and permit fluid to fill the uid eylinder body. Bleed out all air by opening a bleed-off valve, removing the valve cover until fluié flows out constantly, Close the discharge valve and start the unit in operation. Any roughness will probably be from trapped sir, or from starva- tion (insufficient fluid getting to pump). Remove these troubles before permitting the pump to sun continuously A PULSATION DAMPNER. A Pulsation Dampner, properly selected, correct- ly precharged, and located at or on the pump is @ very worthwhile investment. Longer life for valves, springs, and plungers with reduced surges and a gen- erally quieter installation are the dividends. We strongly secommend their usePREVENTIVE MAINTENANCE INSTRUCTIONS DAILY MAINTENANCE 1. Check the level of the crankcase lubricating oil Modet HP-160 or HP-250 pump requites a top quality turbine oll approximating 76 ss.uwv. at 210° F. in viscosity. We recommend a straight mineral oil which many refer to as “turbine” oil because of its exceptionally high quality and good characteristics Flash Point : + 508° F, Fire Point 565° F Pour Point <2... s....0++.. plus S® F., max Viscosity @ 100° F. (aybolt) 762 SS. Viscosity @ 210° F. (saybott) 76.7 S$. Viscosity Index Fone 95.0 Carbon Residue, max... DT tom ColorgAS.TM maxes... 2130 Neutralization Number... 18 Rust Preventive Characteristics =... Passing Distilled Water) Oxidation Inhibitor «0.4... sees. Added Foam Suppressant Dol Added Rast Inhibitor 0. ‘Added If “turbine” oil meeting the above requitments is not available, straight mineral motor oil, S.A.E. 40, ‘of top quality may be substituted in temperate climates on an emergency basis Lubricant to meet AG.M.A. No. 4. Change oil two weeks after start up. Then change every six months thereafter, or promptly alter entry of foreign matter in the erankcase. 2. If a stuffing box force-feed lubricator is in- stalled, check the oil Ievel. Fill if necessary. Use rock drill oil in the force-feed lubricator. (Refer 10 ES-116 for rock drill oil recommendations for lmproved plunger packing recommendations.) 3. Use a spanner wrench to tighten the stuffing box unit. It should be wrench-tight at all times. The packing used in this pump is the hard core type, and must be tight always. 4. Keep the pump clean. (See No. 6 under Monthly Maintenance.) MONTHLY MAINTENANCE 1. Drain and refill the crankcase every six months, or whenever foreign matter enters the crank end, After starting 2 new pump, the crankease should be drained and refilled after the fist two weeks of operation, 2. Wash the crankesse air filter and erankease oil filter in kerosene. 3. Inspect the pump valves for signs of wear Worn discs may sometimes be flipped over. Valve springs should be replaced if worn, broken, or bent ut of shape. Seat faces may show uniform wear — but must be replaced if fluid-cut, or grooved. 4. Crankshaft bearings and connecting rod wrist pin should be checked for excess play and correc- tive measures taken as explained elsewhere in this manual 5. Tighten all studs, nuts, and capscrews. Check for gasket leaks and inspect all connections. Observe stuffing box and plunger for signs of excess grooves, for damage. Replace if worn, 6. Keep the pump clean, It will aid in spotting ‘troubles before they become serious. Keep the stuff- ing box sump drain cleen. 7.Use only genuine Wheatley replacement parts 8, Once each month drain all oll into a clean container. Remove and clean oil filter to which the lube oil pump is connected. ‘This filter unit can be removed by unthreading it from the frame (from the outside) and withdrawing entire unit, The unit has two screens. Remove all sludge. Clean the crankcase sump. Filter the oil, as itis returned to the pump using a fine strainer or filter cloth, If water is present in the oil, discard the old oil and replace with clean fresh oil In any case, refill the pump with clean fresh oil every six months, or oftener, if contaminated.GENERAL MAINTENANCE ‘This pump has been designed to simplify main- tenance and make service easy. Preventive main- tenance and overhauls before serious troubles occur will reduce operating costs. The following section outlines the various steps necessary for the removal \ and replacement of all parts. If an overhaul i re- asa wat Rone aired, follow the specific instructions cacefully OL FILTER UNIT eat Ro Contact the factory if additional information is needed GENERAL INSTRUCTIONS DISCHARGE VALVES lished without removing the valve seat. If it is neces: sary to remove the discharge valve seat, the plunger ‘The discharge valve is located just beneath the should be rolled back out of the way. CAUTION: cover in the upper part of the fluid cylinder body. Be careful not to mar the reamed valve seat deck or Replacement of the spring or disc can be accomp- the internal bore of the fluid eylinder. Tn coven ‘ve riuio cruinpeR ‘yee ‘Ww Fuwio_cvuinoea CROSS-SECTION OF FLUID CYLINDERS Fig. 2SUCTION VALVES ‘The suction valve is accessible after removing the discharge valve. To get the plunger out of the way, rotate the pump until the plunger reaches back posi tion. Stop it before it starts its forward stroke. After the plunger has been retracted, the next step is to remove the valve stem nut and lift out the ceage, spring, dise, and spacer. Seat removal is ac- complished by the use of a special tool available from the factory, When installing valve seats take care 10 avoid damage of tapered deck seating surface. Valve seats should be DRIVEN into the seat deck until firmly seated. This is done, by using an old dise in its regu- lar position and driving with a piece of pips and a ‘hammer. CAUTION: Never drive on the valve stem and do not use any method which will distort valve seat. Taper surfaces must be CLEAN AND DRY! Use clean solvent or diesel fuel. Then wipe dry with a clean rag before assembly. es Fig. 3 INSTALLATION OF SUCTION AND DISCHARGE WAIVE SEATS: Fig. 4REMOVAL OF PLUNGER REMOVAL OF PLUNGER Fig. 5 PLUNGERS Plungers on the “L” and ““M” Models are remov- ed through the fluid cylinder bore. First, remove the cylinder head. Then unscrew the plunger from the pony rod by using @ pipe wrench or chain wrench on the knurled portion of the plunger. CAUTION: Apply the wrench to the knurled Fig.6 WIPER 80x CAP SCREW GLAND. i seaL— pony roof a > O-RING WIPER BOX surface only and handle the plunger carefully. Any nicks in the main body of the plunger will cause prompt and frequent packing failure. Be especially careful of damaging solid ceramic plungers. These are easily broken where the ceramic body is bonded to the metal shank. Plungers and stuffing boxes for “H” Models are removed together-as a unit, as shown in Fig. 5. WIPER BOX ‘The wiper box is held in the power frame by cap screws. After removing the pony rod and the wiper box gland, the wiper box will slide out. To replace the wiper box seal, the pony rod need not be re- moved. It is necessary to disconnect the plunger. CAUTION: Install the seal with the lip turned toward the crosshead. An oil seal is located in the ‘outer face of the wiper box gland. The lip of this seal faces the fluid end stuffing box, to prevent any leakage from entering the power end. Gland nut should be tightened metal to metal,—8e LUBRICATION OIL PUMP ARING HOUSING OW PRESSURE RELIEF VALVE __oW_ pressure ‘AGE 3 —olL PUMP DAIVE PIN cor | wp oi PUMP: N N PRESSURE ABWUSTING soREW —RISENN WASHER! ih SUCTION CHAMBER AN \ im spring] PY Hi Ny ReLer vaLve ——| LUBRICATION OIL PUMP ‘The oil pump is an integral part of the power fame. It is driven by a slotted shaft which is fitted fn the crankshaft, and the righthand bearing hous ing, {¢ has its own filter, oll pressure gauge, and rele valve. This pump draws oil through the filter located in the oil reservoir and discharges into the erankhatt. If there is a loss of oil pressure, first remove the oil pump. This is done by removing the pump cover capscrews and sliding pump out of the bearing housing. Inspect the vanes and vane springs. Replace if worn. Clean the oil suction filter. The oil pump is iectly connected to the crankshaft of the pump, by 4 drive pin. The oil pressure will vary with the speed. ‘of the crankshaft. It will also vary with the type oil used and the oil temperature. A safe oil pressure ange is from 20 to 70 psi. A solfreversing ring is provided which redirects the oil flow if the ditection of crankshaft rotation is, accidentally reversed for any reason. Thus, failure due to no cil pressure is prevented if the pump is, accidentally run backwards. We do not recommend backward operation. Observe ditection-of rotation arrows cast on the power frame. After the pump has been loaded at full speed and is thoroughly warmed, the lube oil. pressure ‘ay then be controlled by adjusting the relief valve to provide from 30 t0 45 psi oll pressure.SPECIAL NOTE: If an HP-Series pump which was built at the fac- tory with left hand drive, for example, is to be disassembled in the field to convert to a right hand dive the reversing ring positioning clip must not be reversed 180°. Leave the oil pump cap in its origin- al position in the bearing housing ‘The pressure guage is provided with a low oil pressure shut-down switch. This should be connect- ed to either the holding coil on a magnetic starter {automatic type) for the electric motor. Or, if a gas CRANKSHAFT BEARINGS Adjustment of the tapered roller crankshaft bearings on opposite sides of the pump is accomplished by using varying thicknesses of bearing housing gaskets. These gaskets are available in thicknesses of 1/16", 1/32”, 1/64”, and .00S”. The correct adjustment is reached when the bearing REMOVAL OF CRANKSHAFT engine is being used, the shut-lown switch should be wired to ground the magneto, in the event of Jow oil pressure. CRANKSHAFT ‘The crankshaft is removed through the bearing housing opening, First, remove the connecting rod caps and posh the remainder of the connecting rod assemblies forward all the way. Second, remove the crankshaft bearing housings by loosening all of the ‘cap screws, using two as jack screws in the holes provided. Third, remove the lube oil pump. Fig. 8 housing cap screws have been drawn up tight and only the slightest drag is noticeable when the crankshaft is rotated. ‘To remove the bearings, the crankshaft must be removed first. The old bearings may be pulled from the crankshaft and the outer race from the bearing ‘housing by use of a bearing puller. REMOVAL OF BEARING CUP FROM HOUSING Fig. 10New bearings may be installed as follows: Expand the bearing inner race by heating it in hot oil at 300°F.: drop it over the shaft and seat into position using a pipe sleeve and hammer. Shrink the lapered roller bearing outer race by packing it in ‘ry ice for about one hour, then drop it into the beating housing. CAUTION: Check the tapered bear- ing outer race to see that there is no slippage in the beating housing. If slippage or rotation has occured, the bearing housing should be replaced. If a hydrau- lic press is available, a preferred method is to press races into place, using no heat. Races must solidly abutt the adjacent shaft or housing shoulder. Never use a flame on races or rollers. Be sure all parts are Clean before assembly. Crankshaft Diam. @ Tapered Roller Bearings HP-160 Pump .............. 4,003” to 4.002” HP-250Pump «0.2... 4.878" to 4.87" CONNECTING ROD AND CROSSHEAD ASSEMBLY If the crankshaft has already been removed from the pump, the connecting rod, with its wrist pin and crosshead may be removed, withdrawing all thru the rear end of the frame. But, if the crankshaft has not been removed (removal not desired), then the crosshead, wrist pin, and rod may be removed, following this sequence: 2.) Remove connecting rod cap. Remove wiper box. Tag shims, ete. “LLL Uf CORLLER Hae CROSSHEAD WRIST PIN SECTION (ToP sEcTION view) ) Shove rod and crosshead toward fluid end, until wrist pin is exacily centered at its access hole provided in frame. ©.) Pull waist pin. A hydraulic hollow-spindle jack is desirable. 4) Push crosshead into cradle, Remove thru cradle. ©.) Slowly revolve crankshaft - until crank throw is at its lowest position, f.) Remove balance of connecting rod thru crankcase opening, raising it over the erankthrow as it is pulled out thre the rear Always start with the outside crossheads first ‘Then remove inside one CAUTION: When the connecting rod cxp is removed, special care should be taken to re-install the cap and shell beating in the same position from which they were assembled. (Be sure they are not turned end-forend from original placement). Connecting rod shell bearings aré precision-made, shim-adjustable type. Adjust shims to provide .006" ‘on diameter clearance at each shell bearing. Use “Plastigage” to determine clearance. (Available at you local automotive parts distributor). To replace the connecting sod wrist pin bushing, press out the old bushing, and press in the new bushing. If a tight fit is not obtained, it will be necessary to replace the connecting rod. Ream the ‘ew bushing after pressing it into the connecting rod Until it fits the wrist pin snugly, but does not bind, 2.750" - 2.751” Ream) Crankshaft Throw Diameters . CCrosshead Diameter (For Pin) Weist Pin Diameter =. 4.502” ~ 4,499" 2.7480” ~ 2.7485" +++ 2.7500” ~ 2.1495' Crossheed O.D. 2.7494" 7.491" Power Frame Bore for Crosshead. .. 7.500” - 7.505" Connecting Rod Bolt Torque 115-125 Fi. Ibs,