/tJ~ j;;" 7L

:::Ii \0 tr ? i 1ft -Ea.)

!Lt,ll-J(i t r.! , • .1 tI It v 700 7...i.4

Pump
A Textron Company

TO-60 & TO-60 S L I;

Installation
Operation & Maintenance f

Manual
I!m:II!:mI Pump
A Textron Company
Installation, Operation, and Maintenance Manual

Foreword

The information contained in this manual will enable you to install, operate, and
maintain your Union Pump properly and safely. Study this manual as well as any
supplements provided in the final data package to ensure satisfactory and safe
operation of the pump.

Deviation from the recommendations and instructions in this manual and other
data supplied by or referred to by UNION PUMP COMPANY may result in a
hazardous situation. UNION PUMP COMPANY is not responsible for the
consequences resulting from such deviation from operating and maintenance
recommendations.

Read all instructions including Notes, Cautions, and Warnings carefully before
starting this pump. The following definitions apply to these terms as used in this
manual.

NOTE: A Note provides specific information and must be read

before continuing.

CAUTION: Provides information necessary to prevent damage to

equipment or personal injury.

WARNING: Provides information necessary to prevent serious

personal injury or death.

Contact Union Pump Company if you have questions regarding the installation,
operation, maintenance, or storage of this pump.
Unlan Pump camp_"¥' Installation, Operation, and Maintenance Manual

TABLE OF CONTENTS
Introduction... . 2
Information About This Manual....................... . 2
Pump Description ..3

Section 1 1nstallation 3
A. Handling. .. ..3
B. Storage . 3
C. Location . 5
D. Coupling Alignment .5
E. Piping 6

Section 2 . Operation . ....................................... 12

A. Preparation For Start-Up . .................................... 12
B. Priming The Pump . ......................... . 16
C. Start-Up....... . . 16
D. Break-In Period . . 17
E. Abnormal Environmental Conditions . ....................................... 18
F. Trouble Check-LisL . ............ ..19

Section 3 Routine Maintenance ... 23

A. Performance Records . 23
B. Routine Inspections & Servicing.. ............................23

Section 4 Disassembly and Assembly Instructions 26

A. Packing, Plungers and Stuffing Boxes...... . 26
B. Fluid Cylinder..... 30
C. Valve Assemblies . 34
D. Power End . 37

Page 1

,.
Union Pump Comp_ny Installation, Operation, and Maintenance Manual

INTRODUCTION

INFORMATION ABOUT THIS MANUAL

This manual provides installation operation and maintenance instructions for

the UNION PUMP model TD-BO Reciprocating Power Pump. This pump is
manufactured in various configurations so this manual must be used in
conjunction with specific drawings, parts lists and other data provided as part
of the Final Data Package for a specific pump.

Infomnation concerning sub-assemblies and equipment not manufactured by

UNION PUMP is provided as part of the Final Data Package.

Read the instructions carefully before starting and operating this pump. Be
sure to read and understand all Notes, Cautions, and Warnings. The
following definitions apply to these terms as used in this manual.

Note: A Note provides specific information and must be read before

continuing.

Caution: A Caution provides information necessary for preventing

damaQe to equipment.

Warning: A Warning provides information necessary for preventing

iniury to a person.

Please contact UNION PUMP COMPANY with any questions regarding this
pump or the installation, operation or maintenance of it.

Page 2
Union Pump Camp_1"V' Installation, Operation, and Maintenance Manual

PUMP DESCRIPTION

The UNION PUMP Model T0-60 is an intermediate capacity high-pressure

reciprocating power pump.

SECTION 1 INSTALLATION

A.HANDLING

Lift the pump assembly using the eye bolts in the top of the power frame, or
baseplate, or by slings under the power end.

CAUTION: Lifting eyes may be provided on the motor. These are

designed for lifting the motor only. Never lift the pump assembly
using these liftino eves.

CAUTION: Never lift the pump by the fluid cylinder. Lifting by the
fluid cylinder is likely to cause misalignment and improper pump
operation.

WARNING: The pump assembly may not be balanced when lifting.

Alwavs provide proper support so that the pump cannot tip.

B.STORAGE

Prior to shipment, the pump was prepared for a six-month storage period in
an average environment. If, prior to start-up, the pump will be exposed to
more severe conditions, such as high humidity or salty air; or if the idle
period will exceed six months, the pump should be prepared for long term
storage as outlined below.

If the pump is idle for a period of time, protect it from moisture, sand and
other foreign matter using the following procedures.

If the pumpage is water or a similarly corrosive liquid, it should be completely

removed from fluid end. This may be accomplished by removing suction
valves or stUffing boxes and drying the cylinder, or by forcing a suitable non­
corrosive liquid from the suction manifold into the pumping chambers,
thereby forcing the corrosive liquid through the discharge valves and into the
discharge line

Page 3
Unlan Pump Camp.ny Installation, Operation, and Maintenance Manual

NOTE: The following storage recommendations apply only to the

pump and may not be appropriate for furnished auxiliary equipment
Consult the manufacturer's instructions for auxiliary equipment
supplied with this pump.

1. General Considerations

a. Store the pump off of the ground on skids or a pallet.

b. Store in a clean dry place away from blowing dust or sand.

c. Do not expose stored pump to temperature extremes.

NOTE: Environmental extremes cause a condensation bUild-up in

the internal pump cavities which can result in premature pump
failures.

2. Short Term Storage (Up to 6 weeks)

a. Remove power end breather and oil filler plug.

b. Spray a heavy fog of a light preservative in oil filler hole until fog
comes out breather hole.

c. Plug holes and store breather in the plunger well area

d. Place a heavy plastic or canvas cover over the complete unit.

3. Long Term Storage (Over 6 weeks)

a. The fluid end has been disassembled and blown dry prior to
shipment. Both suction and discharge openings are sealed with a
plastic plug.

b. Spray internal power end machined surfaces with a light rust

preventative. Coat all external machined surfaces with a suitable
rust preventative, such as CRC, SP-400 or equal.

c. Place a heavy plastic or canvas cover over the complete unit.

d. Inspect unit each six months (or as required by environmental

conditions), using the following procedure:

Page4

, .
Union Pump Comp.ny Installation, Operation, and Maintenance Manual

1. Drain oil from the crankcase.

2. Remove crankcase cover using care to prevent gasket

damage.

3. Remove plunger cover and clear the plunger well of parts or

packages that may interfere with the crosshead stubs
when the crankshaft is rotated.

4. Rotate crankshaft by hand approximately 1-1/3 turns,

examining internal parts. Rust on any part must be
removed and a suitable rust preventative applied.

5. Inspect external surfaces, especially unpainted machined

parts (couplings, shafts, crosshead stubs, etc.) and restore
broken or damaged coatings.

6. Place parts and packages back in plunger well and install

plunger cover.

7. Install crankcase cover and gasket.

8. Pour vapor emitting oil into crankcase.

9. Check all openings to see they are properly sealed.

10. Place heavy plastic or canvas cover over unit. If plastic or

canvas cover is not used, reduce inspection period to three
months.

C. LOCATION

Install the pump in a well-lighted, clean and dry location as close to the fluid
supply as practical. Provide ample room to inspect and dismantle. Make
the unit accessible to equipment required to lift the heaviest component.

D. COUPLING ALIGNMENT

In cases where the pump is furnished with driver such as gearhead motor, or
motor and speed reducer connected to the pump with couplings, the pump
and driver shafts or couplings must be carefully aligned.

Page 5
 Unlan Pump CDmp_"¥' Installation, Operation, and Maintenance Manual

When a base is furnished, the pump and driver are aligned before shipment;
however, this alignment may be impaired during shipment and handling or
when setting to foundation. Alignment should be checked and if there is any
misalignment, loosen bolts which secure driver to base and realign using
shims as required for vertical alignment. Be sure any shimming is done so
that no strains will be thrown on pump or driver when mounting bolts are
retightened If there is any difficulty in avoiding strains, it will be found that the
base has been strained on the foundation, in which case loosen foundation
bolts and shim under base as required to eliminate strains in base before
tightening bolts which secure pump and motor to base. Refer to coupling
manufacturer's specifications for proper tolerances.

E. PIPING

The piping recommendations given in this section are of a general nature.

These recommendations should be followed whenever practical. Typical
piping diagram is shown on page 11.

NOTE: UNION PUMP COMPANY CANNOT ASSUME

RESPONSIBILITY FOR THE SYSTEM INTO WHICH THE PUMP
IS INSTALLED. That responsibility lies with the system desinger. It
can only be said that violation of these guidelines has often resulted
in system and pump problems.

CAUTION: All piping must be supported independently from the

pump. Do not allow the pump to support the piping. Piping must
align with the pump flanges. Never force piping into place at inlet or
discharge flanges.

Pipe lines should generally not be smaller than pipe connection sizes on
pump, and larger size lines, with eccentric increasers or reducers at the
pump, may be required under some conditions. Lines should have a
minimum of turns and fittings, and if valves are used, they should be gate
valves. Strainers in suction line should be avoided if possible, if necessary,
sufficient allowance must be made for pressure loss through strainer under
the most clogged condition at which it will be used and adequate attention
must be provided to avoid excessive clogging. Suction line should be kept
as short as possible.

Page 6

,.
UnlDft Pump cam~.", Installation, Operation, and Maintenance Manual

WARNING: All suction lines should be flushed prior to connecting

to the fluid cylinder Any foreign material not removed from the
suction line will be drawn into the cylinder This will cause damage
to the pump, and oossible iniuN to oersonnel.

The total NPSH (pressure above vapor pressure of liquid) required at the
end of the suction line is the sum of the NPSH required by the pump and the
suction line NPSH requirements. The suction line requirements consist of
the friction losses and the pressure required to produce the acceleration of
the liquid in the line so it will follow the normal flow pattern of the pump. The
acceleration requirement is usually much greater than the friction
requirement, and is proportional to the pump speed (RPM), line velocity and
the line length. Therefore as pump speed, displacement,
and line length increase, it is necessary to decrease line velocity (increase
pipe size) to compensate, and/or to provide increased pressure at the end of
the line. Keeping the suction line short minimizes these requirements.

An inadequate suction line or insufficient suction pressure for the line will
result in a starved condition of the pump, with loss of capacity and shock
operation which may be damaging to the pump.

An inadequately sized discharge line in relation to line length will cause

excessive pressure pulsation and line vibration, due to acceleration
reqUirements which are affected by the same factors as in the suction line.

These acceleration requirements in the suction and discharge lines may be

greatly reduced by the use of pulsation chambers or dampeners in the lines
at or close to the pump, and are especially helpful where long lines cannot be
avoided. These should be of a type suitable to the liquid and operating
conditions.

Pipe connections should be properly made to avoid air or liquid leaks.

Piping should be arranged and supported to avoid undue strains on pump. It
is recommended that pipe couplings or flanges be installed close to cylinder
when making pipe connections to pump to permit easy removal of the fluid
cylinder from the pump when required.

Page 7

, '
UnKln Pump Camp.ny Installation, Operation, and Maintenance Manual

Reciprocating Pump Piping Guidelines

Suction Piping Should:

1. Be as short and direct as possible.

2. Be one or two pipe sizes larger than pump suction connection.
3. For a triplex pump, have a velocity less than 2 FUSec for speeds
up to 250 RPM, 1-1/2 FUSec for speeds up to 330 RPM and 1
FUSec for speeds above 330 RPM.
4. Contain a minimum number of turns. Necessary turns should be
accomplished with long-radius elbows or laterals.
5. Be designed to preclude the collection of vapor in the piping. (No
high points unless vented.) (Use eccentric reducer at pump
cylinder with flat side !m.)
6. Be designed so that acceleration head (H a ), friction loss (H r), and
pump NPSH required (NPSH R) do not exceed the NPSH available
(NPSHA ) from the system. Acceleration head is defined and
discussed in the Hydraulic Institute Standards. In equation form:

7. Include a suction bottle or suitable pulsation dampener installed

adjacent to pump cylinder if it is found that the acceleration head is
excessive. Care must be taken in the application of dampeners to
suction systems since many dampeners are not suitable for low
pressure application.

Discharge Piping Should:

1. Be as short and direct as possible.

2. Be one to two pipe sizes larger than pump discharge connection.
3. Have a velocity not exceeding three times the suction velocity
4. Contain a minimum number of turns, utilizing long-radius elbows
and laterals where possible.
5. Include a suitable pulsation dampener or provisions for adding a
dampener at a later date adjacent to the pump cylinder.
6. A relief valve should be provided between pump and check or
shut-off valve, close to pump. It must be sized to pass the entire
pump capacity with a cracking pressure set about 10% over
specified discharge pressure, and an accumulation pressure not
exceeding 10% of cracking pressure

Page 8
Union Pump CGrnp_ny Installation, Operation, and Maintenance Manual

WARNING: This positive displacement machine should not

be oDerated aaainst a dead end discharae.

7. A by-pass line, with a shut-off valve should be provided from

discharge line to suction supply source (connected between pump
and check valve). It serves the purposes of permitting lubrication
to reach critical pump parts during start-up without subjecting
these parts to high loads, permitting driver to reach full speed
under low torque conditions, and permitting all pumping chambers
of fluid end to become fully primed.

Multiple Units:

When two or more pumps are connected to a common suction andlor

discharge line, the capacities of all pumps which run simultaneously must be
added for determination of line velocities. Care must be exercised to
prevent a mutually reinforcing pressure wave from multiple units. To avoid
this possibility, independent lines are often installed.

The above guidelines represent a combination of Hydraulic Institute

recommendations and criteria established by experienced designers of
systems containing reciprocating pumps.

NOTE: Union Pump Company cannot assume responsibility

for the system into which the pump is installed. That
responsibility must lie with the system designer. The above
guidelines are offered only as an aid to those involved in the
system desian.

Acceleration Head Phenomenon

Piping for a reciprocating pump required more consideration than piping for
a centrifugal pump. Because the fluid in the suction line is pulsating
(accelerating and decelerating), a certain amount of energy is required to
produce the acceleration. This energy is in addition to the friction loss and is
usually referred to as "acceleration head".

If sufficient energy is not available to accelerate the liquid in the suction line,
the liquid will flash, the suction and discharge lines may shake, and the pump
will operate noisily. It is possible to fracture a fluid cylinder with the high
pressure surges that occur in the cylinder when the fluid is flashing in the
suction line.

Page 9
Union Pump Comp.ny Installation, Operation, and Maintenance Manual

We are able to calculate the head required to accelerate the fluid with the
following empirical equation:

Ha = LVNC/32.2 K

Ha = Head (in feet of liquid pumped) to produce the required

acceleration

L = Actual length of suction pipe, feet - (not equivalent length)

v = Mean velocity of flow in suction line - ft./sec.

N = RPM of pump

C = 0.066 for Triplex TD-BO

K = 2.5 for relatively compressible liquid (ethane)

1.5 for liquid with almost no compressibility (deaerated water)
2.0 for most hydrocarbons
1.5 for amine, glycol, water

This equation is based on a relatively short, non-elastic suction line.

It will be noted that as the pump speed is increased, both N and V increase.
Therefore, Ha varies as the square of pump speed. Ha also varies directly
with L.

To determine the amount of NPSH required in the suction vessel, it is

necessary to add three factors.

Total NPSH R = Pump NPSH R + Friction Loss + Acceleration Head

It is possible to reduce the acceleration head by installing a suitable

pulsation dampener in the suction line near the pump.

Page 10
Union Pump Camp.ny Installation, Operation, and Maintenance Manual

SYSTE~ nESIGN CONSIDE~ATIONS

A. IS THERE ENOU~H HEAD TO PROVIDE NPSH RElJUIRED BY THE

PU~P AND OVERCO~E ACCELERATION HEAD. fRICTION LOSS?
(NPSH = SUCTION HE"D-V"POR PRESSU~E)
B. IS THERE A 'JEIR PLATE TO HELP RELEASE T~APPED GASES?
C. IS THERE A VORTEX ~REA~ER1
D. IS SUCTION VELOCITY 'tIITHIN RECOMMENDED LIMITS?
elf NOT. CAN A LAAGE~ SUCTION UNE BE USED1)
E. ARE BENDS FEll? DO THEY HAVE LARGE RADII?
F. IS SUCTION VALVE FULLY OPEN.,
G. IS THE~E A PULSATlI:t.I BOTTLE (O~ AT LEAST PROVISION
fOR OND NEAR PUMP SUCTlON1
H. IS THERE A PULSATION DA"PENER (DR AT LEAS PROVISION
FOR OND NEAR PU~P DISCHARGE?
I. IS THE RELlEF VALVE SIZED TO PASS TOTAL PUMP
FLO" AT ~ELlEF VALVE F'~ESSU~E SETTINIi +<101.1
J. IS THERE A CAPACITY CONTROL VALVE?
(,ULLY OPEN FoR STA~T-UP>
~, ARE ALL INLETS BELOW "INIMUM LlQUID LEVELS?
L. IS: THE~E A CHECIC VALVE?
". IS DISCHARGE VELOCITY U~ITED TO 3X SUCTlON?
AlIIO A~E THE NUIo'IBE~ OF TU~NS L1HlTEI]'
A.1II0 IS THE LINE FULLY SUPPORTED.,

ELEV=A
B TANK INLET
K E

D J

DJSCHA~GE

REF, DATA LlNE L

E SUCTION

F PU~P
FLUlD CTUNDER

Typical Piping Diagram

Page 11
Union Pump CGmp_ny Installation, Operation, and Maintenance Manual

SECTION 2 OPERATION

A. PREPARATION FOR START-UP

1. Removal of Protective Coating

Remove all protective coatings that have been applied to the

pump which would interfere with pump operation. All exposed
machined surfaces are coated before shipment and this coating is
soluble in petroleum solvents. Of particular importance are
crosshead stubs. They should be clean and smooth to prevent
damage to oil seals.

2. Inspection After Storage

If the pump has been in storage or idle for a long period, the drive
and fluid end should be inspected to make sure that no dirt or
debris has accumulated in them. This can be done by removing
the crankcase cover and fluid cylinder covers, and making a visual
check.

CAUTION: The importance of having the unit clean prior to

initial operation cannot be overemphasized.

3. Final Piping Checks

WARNING: All suction lines should be flushed prior to

connecting to the fluid cylinder. Any foreign material not
removed from the suction line will be drawn into the cylinder.
This will cuase damage to the pump, and possible injury to
personnel.

Make sure all piping joints are tight (including drains) so they do
not permit any leakage of liquids out of, or air into, the piping
system. Verify that a relief valve is installed in the discharge line,
and is set to the correct pressure.

4. Crankcase Oil

Fill crankcase to proper level indicated on oil level gage. Use a

high grade of 10W40 motor oil.

Page 12
Union Pump Com.,."" Installation, Operation, and Maintenance Manual

5. V-Belt Installation and Adjustment

If the pump is V-belt driven, be sure belts and sheaves are clean
(free of all paint, grease or dirt). Remove any rust or burrs in the
sheave grooves caused by handling. Be sure the drive rotates
freely, and has sufficient clearance around all components. Install
and adjust V-belts per the following instructions.

WARNING: Be sure that power to the motor is off and locked out
before removing the V-belt guard and performing maintenance on
the belts and sheaves.

CAUTION: Do not combine used and new belts on one drive.

Keep used belts for emergency replacement only. Use only a
matched set of new belts.

a. Installation

1. Move motor toward pump until belts can be easily installed

by hand.

II CAUTION: Do not pry or roll belts on as this may damage belts.

2. Move motor away from pump until belts are tight. (See
"Adjustment" section).

3. Check to be sure that motor and pump shafts are parallel.

4. Keep belts free from dirt and oil.

II CAUTION: Do not use belt dressing.

b. Adjustment

1. Adjust drive to obtain all belt slack on one side of span.

2. Measure the span.

3. MUltiply by 1/64. (This is proper deflection.)

Page 13
Union Pump Com~ny Installation, Operation, and Maintenance Manual

Figure #1

4. At the center of the span, apply a force at right angles to the

span in accordance with the following table.

Cross Section Small Pulley Diameter Force'

Inch mm Lbs. Newton
3V 2.65-3.65 67-93 3-4 13-18
3V 412-69 105-175 4-5 18-22

5. Tighten drive until proper belt deflection is obtained.

6. Measure each belt individually. Tension must be the same

for all belts in drive.

'NOTE: A new set of belts should be tensioned 1/3 greater than

the force listed above.

NOTE: V-belts must be operated under proper tension. Too little

tension will permit excessive slippage resulting in loss of life and
power. Too much tension will cause short life. Proper tension is
just slightly above the point where slip is eliminated. This can best
be determined by measuring speed ratio at no load and at full
load. The change in speed between no load and full load should
not exceed 1 percent. During the first 36 hours of operation, the
tension must be adjusted to compensate for initial stretch and
wearing-in or seating of the belts in the grooves. Spare belts
should be stored in a cool, dry area.

6. Direction of Rotation

The proper rotation is so that the top of the crankshaft moves

toward the fluid end as indicated by rotation arrows on the pump.

Page 14
Union Pump Company Installation, Operation, and Maintenance Manual

CAUTION: Liquid will be pumped in the fluid end regardless of the

direction of crankshaft rotation. However, the wrong rotation will
result in inadequate lubrication of the power end components and
a shorter pump life.

7. If the pump was shipped from the factory with plungers and
packing not installed, preform packing/plunger installation. (See
Section 4, Item A for Disassembly and Assembly instructions.)

Page 15
Union Pump Camp_"., Installation, Operation, and Maintenance Manual

B. PRIMING THE PUMP

To operate properly, all pumping chambers of the pump fluid end must
be fully primed.

CAUTION: A pump which is not completely primed will cause

piping to vibrate, gages to flutter excessively, and may be noisy.
Capacity will also be low. Continued operation will damage the
pump and pipinq components.

The following start-up procedure will normally prime the pump

satisfactorily. Before the pump is started the suction line must be
filled and pressurized with pumpage, forcing the pumpage to flow
completely through the fluid end and into the discharge and by-pass
lines.

C. START-UP

After all checks have been made, you are ready to start the pump.

1. Normal Start-Up

Prior to start-up, the by-pass valve, suction block valve, and

discharge block valve must be fully open. Start pump and operate
a few minutes with no load to allow lubrication to reach power end
components and to allow fluid end to become completely primed.
Then slowly close by-pass valve, allowing pump to be gradually
loaded.

2. Avoid Starting Pump Under Load

Page 16
UnlDn Pump camp_"¥' Installation, Operation, and Maintenance Manual

CAUTION: Starting a power pump under load is a poor practice

and should be avoided. The disadvantages of starting under load
are:

a. Oil is not flowing through pump lubrication system.

b. Bearings have not had an opportunity to establish an oil film.

c. The load on bearings (and other power end components) and

on fluid end components will be higher than operation loads
because of the inertia of all rotating parts and the inertia of all
fluid in suction and discharge lines. This fluid inertia can be
quite large for long lines.
CAUTION Cont.:
d. Drive components (gears, belts, and couplings) will be loaded
above their design because of inertia mentioned above.

e. Motor may be loaded beyond its capacity.

f All pumping chambers of the fluid end do not have an

opportunity to become primed. This can lead to reduced
caoacitv and severe vibration in suction and discharae oioina.

D. BREAK-IN PERIOD

Each pump has been run tested prior to shipment. It is not necessary
that an additional break-in test be imposed. However, the maximum
allowable oil temperature in the power frame should not exceed 160°F
(73°C).

CAUTION: Do not run pump under load when crankcase oil

temperature is below 30°F (O°C) or above 160°F (73°C). Pump
can be run at no load until oil temoerature reaches 30·F (O·C).

Any unit that has undergone a major repair to the power frame
requires a break-in period before it is placed back into service. The
break-in procedure should consist of the following steps.

1. Run the unit for 15 minutes with no load (0 psi differential

pressure).

Page 17
Unlan Pump Camp.ny Installation, Operation, and Maintenance Manual

2. Run the unit for 15 minutes at 1/4 load (25% of the specified
discharge pressure).

3 Run the unit for 30 minutes at 1/2 load (50% of the specified
discharge pressure).

4. Run the unit for 30 minutes at 3/4 load (75% of the specified
discharge pressure).

If the pump operates satisfactorily at each of the pressures, it may be

operated at full load (100% of specified discharge pressure).

E. ABNORMAL ENVIRONMENTAL CONDITIONS

1. Freezing Conditions

To prevent freezing of liquids in fluid cylinder and lubricating oils

from becoming too viscous, the pump should be protected from
freezing temperatures. If exposure to temperatures below 30°F
(DoC) is unavoidable, provisions must be made to warm the power
end, fluid end. If pumpage will freeze during shut-down periods,
the entire system must be drained to prevent damage to pump
and piping.

2. Dusty Conditions

Air-borne abrasives will deposit themselves on plungers and

crosshead stubs, shortening the lives of plungers, packing, stubs,
and seals; and may be drawn through the power end breather,
contaminating oil and shortening bearing life. Efforts should be
made to protect the pump against dust and grit

3. Corrosive Vapors

Efforts should be made to minimize the exposure of the pump to

corrosive gases to prevent contamination of power end and
lubricator lubricants.

4. High Humidity

Page 18
Unlan Pump Camp_ny Installation, Operation, and Maintenance Manual

Pumps exposed to high humidity, unless operated continuously,

will accumulate condensation in the power end and lubricator.
Periodic samples of oil should be taken from drain connections,
and when water is detected, the oil should be changed.

5. Pressurizing Power End

Pressurizing the power end to exclude contaminants requires a

special oil level gage.

CAUTION: Do not attempt pressurization of power end with the

standard oil level gage. All oil will be forced out through the vent
hole in the tOf) of the qaqe.

F. TROUBLE CHECK-LIST

Symptom or Trouble and Probable Causes See Remedies

on pages 20-21
Low Discharge Pressure
1. Clogged suction system. 7
2. Worn nozzles or orifices. (Jet cleaning applications) 1
3. Worn seat or stem in pressure regulator or relief valve. 3
4. Pump not fUlly primed. 10
5. Low pump speed. 2
6. Motor improperly wired. 28
7. Excessive packing leakage. 5
8. Foreign material under pump valves. 6

Low Capacitv
1. Clogged suction system. 7
2. Foreign material under pump valves. 6
3. Low pump speed. 2
4. Gas entering fluid cylinder. 8
5. Insufficient suction pressure. 9
6. Pump not fully primed. 10

Knocking in Power End

1. Low oil level. 11
2. Crankshaft bearings out of adjustment. 12

Page 19
Union Pump Camp_ny Installation, Operation, and Maintenance Manual

3. Loose plunger or plunger stub. 13

4. Pump running backwards. 25
5. Worn crosshead pin bearings. 14
6. Loose sheaves or bushings. 4
7. Sound being transmitted from fluid end. See Next Section

Knocking or Pounding in Fluid End or Excessive Pulsations

1. Insufficient NPSHA 9
2. Gas entering fluid cylinder 8
3. Broken valve spring or foreign material under valve. 6
4. Excessive valve lift 21
5. Relief valve or other accessories in discharge piping
causing noise. 19

Excessive Packing Wear

1. Improper packing. 27
2. Improper packing installation. 17
3. Plunger misaligned with stuffing box. 22
4. Abrasives in fluid. 20
5. Excessive fluid temperature. 20
6. Improper packing lubrication. 17
7. Rough or scored plungers. 21
8. Worn stuffing box bushings. 21
9. Wom stuffing box. 21
10. Excessive pump pressure. 18

Excessive Temperature in Power End

1. Too much or too little oil in power end. 11
2. Ambient temperature too high. 23
3. Power end exposed to sun's rays or to heat radiating
from nearby equipment 24
4. Pump overloaded. 18
5. Running too fast 2
6. Suction pressure too high. 15

V-Belts Slip
1. Belts are loose. 2
2. Discharge pressure too high. 18

Page 20

, .
 Union Pump Comp_ny
Installation, Operation, and Maintenance Manual

3 Belts are worn out. 21

4. Sheaves are worn out. 21
5. Motor shaft and purnp shaft not parallel. 26

Page 21
 Union Pump Comp.ny Installation, Operation, and Maintenance Manual

Items/Remedy

1. Oversized orwom nozzles will discharge a capacity, at the required

pressure, greater than the pump capacity. This causes the pressure
to drop until the nozzle capacity equals the delivered capacity of the
pump. Recheck nozzle size and number of nozzles.

2. Correct speed to proper value. If belts are slipping, tighten or replace.

3 Check overflow or relief valve or pressure regulator, if liquid is

escaping - shut pump off and check seat and stem for foreign material
or a bad seating surface.

4. Inspect sheaves and bushings - tighten if necessary.

5. Replace packing. Ifwom, replace stuffing box bushings. If weakened,

replace stuffing box spring.

6. Inspect valve assemblies. Clean, relap, or replace components if

necessary.

7. Clean suction filter or strainer. Check suction piping and supply tank
for obstruction or partially closed valves.

8. Check for air leaks in suction piping. Check pipe joints, packing
around valve stems, and instrument connections. Check suction tank
for "vortexing". If air is entering through stuffing box, adjust or replace
packing and/or increase lubrication rate.

9. Increase suction pressure by one or more of the following methods:

Reduce the fluid temperature.
Reduce suction left or increase the fluid level in the supply
tank.
Add a booster pump.

10. Prime all pumping chambers. For a suction lift, a positive suction
pressure may be required to remove trapped air in the fluid cylinder.

11. Fill to proper oil level.

12. Check crankshaft bearing endplay. Remove or add shims as

required. This is not normally required unless a crankshaft, bearings,
shims, or frame caps have been replaced.

Page 22
Union Pump Comp.ny Installation, Operation, and Maintenance Manual

13. Tighten plunger to stub. Connections have right hand threads, torque
value is listed on Chart #2, Section 4, Item D.

14. Check crosshead pin bearings and replace if worn beyond tolerance
shown in "Clearance Chart", Section 4, Item D.

15. Reduce suction pressure.

16. Install packing in accordance with instructions.

17. Follow manufacturer's recommendations for packing lubrication in

Section 4, Item A

18. Reduce discharge pressure.

19. A rapidly closing valve, solenoid valve, or shutoff valve will produce a
water hammer effect. This pressure wave being transmitted back to
the pump will cause knocking. A pulsation dampener on the pump
side of the valve may be required. A different valve may be required.

20. Packing is selected for its suitability to the fluid and the pumping
conditions. If conditions have changed or if corrosive or abrasive
fluids, or fluids at elevated temperatures are being pumped, special
packing may be reqUired.

21. Replace worn parts.

22. Replace parts causing misalignment.

23. Reduce ambient temperature.

24. Install heat shield between pump and heat source.

25. Correct rotation.

26. Adjust motor support legs so that motor shaft is parallel to pump shaft.

27. Install packing recommended for the service.

28. Recheck motor nameplate for proper wiring sequence.

Page23
UnlDn Pump CDmp_ny Installation, Operation, and Maintenance Manual

SECTION 3 ROUTINE MAINTENANCE

A. PERFORMANCE RECORDS

A daily record of pump performance should be kept, particularly when more

than one person operates the unit. The first clue that performance is
deteriorating usually comes from a written record or log. Records should
include any unusual changes in temperature or pressure, or strange noises.
These indicate that servicing may be needed.

B. ROUTINE INSPECTION AND SERVICING

GENERAL:
No piece of machinery can be expected to continue in satisfactory operation
unless it receives proper and periodic attention. The following are
recommendations for routine inspection and servicing under normal
conditions.

1. Daily or Approximately Every 24 Hours of Operation

Check the pump to assure that:

a. Operation is qUiet and smooth.

b. Operating temperatures are normal in both the power end and
the fluid end.
c. Oil level in the crankcase, and gear pac (if so equipped), is
proper.
d. There is no gasket leakage.
e. The packing is not leaking excessively. (Some leaking is
preferred for cooling)
f. There is no fluid accumulation in the plunger well.
g. Packing lubricator is filled to proper level.
h. V-belts are not slipping.
i. Operating pressures are not above specified values.

2. Weekly or Approximately Every 170 Hours of Operation

Check ...

a The oil in the crankcase, and gear pac (if so equipped), for
water or other contaminants. This can be done, if necessary,

Page 24
Unlan Pump Cam~ny Installation, Operation, and Maintenance Manual

while the pump is running, by drawing a small sample from the

drain connection.
If the pump is new or if new parts have been installed in the
power end, the oil should be changed after about 170 hours of
operation. Prior to filling with new oil, the crankcase cover
should be removed and the interior wiped clean. Approximate
oil required equals 2.25 gallons (8.5 liters) SAE10W40 for 0-
115°F (-18 -44°C) ambient temperature range.
b. Strainers and other piping components to see that they are not
clogged. This can be done by monitoring the pressure drops
across these devices.
c Belt tension. Adjust if needed.

II WARNING: Make sure power is off and locked in the off position.

d. Plungers to see that they are all still securely fastened to the
stubs.

II WARNING: Make sure power is off and locked in the off position.

3. Monthly or Approximately Every 750 Hours of Operation

Check.

a. All bolting, especially those on the fluid end of pump. Tighten if

necessary (Refer to the bolt torquing requirements - Chart #1,
Section 4, Item B).
b. The crankcase breather. Clean if necessary. It should be
noted that depending on environmental conditions, this may
need to be done more frequently.

4. Every 3 Months or Approximately Every 2250 Hours of Operation

a. Change the oil in the pump. During the oil change, the
crankcase cover should be removed, the interior wiped clean,
and a visual check made for worn parts and other abnormal
conditions. Also, the torque on connecting rod bolts should be
checked. (See bolt torquing requirements on Chart #2,
Section 4, Item D).
b. Replace plunger packing and bushings (if worn) if leakage is
excessive.

5. Every 6 Months or Approximately Every 4500 Hours of Operation

Page 25
 Union Pump Comp_ny Installation, Operation, and Maintenance Manual

a. If needed, the sealing surfaces of the fluid cylinder valves and

valve seats are to be refinished.
b. Replace any compressed or broken valve springs.
c. Replace plungers if worn, scored or otherwise damaged.
d. Replace crosshead stub seals.
e. Replace belts if slipping excessively.

6. Yearly or Approximately Every 9000 Hours of Operation

It is suggested that the pump be disassembled and thoroughly

inspected.

7. Adjusting Periods for Inspection and Servicing

Severe environmental or operating conditions may require that the

time intervals for inspection and servicing be shortened.

Page 26
Union Pump Camp.ny Installation, Operation, and Maintenance Manual

SECTION 4 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS

WARNING: Before starting disassembly or assembly of any

components make sure that the power to the motor is turned
off and locked in the off position.

NOTE: Refer to the specific drawings supplied in the final

data package when using the following Assembly!
Disassembly procedure. The number in parentheses after
certain steps refer to component parts as identified on the
drawinas.

A. PACKING, PLUNGERS AND STUFFING BOXES

Union pumps are shipped from the factory without plungers and packing
installed, unless otherwise specified.

CAUTION: If pump is shipped with plungers and packing

installed, and is not going to be started for 60 days or more,
plungers and packing should be removed to prevent
corrosion of plunaer and stuffina box surfaces.

The stuffing box most commonly used is a manually adjusted non-lubricated

packing design. Under severe operating conditions an optional mechanical
lubricator is available to automatically provide lubrication to the stuffing box.
If this option is ordered, specific packing instructions will be provided

Packing Ring Forms

Two types of packing designs are generally used depending upon the
service requirements.

1. "V" Ring type packing (Chevron).

2. Die formed cut square type packing.

NOTE: See stuffing box and packing information sheet

supplied with your sDecific DumD.

Page 27
Union Pump CDm~", Installation, Operation, and Maintenance Manual

Packing Joints

"V" ring packing is supplied with male and female adapter rings and must be
installed with lips facing fluid cylinder.

CAUTION: Endless "V" ring packing should not be split, as it

would weaken this tvoe of rina.

Square type packing must be installed with split joints staggered 90 to 120
degrees apart to prevent a leakage path.

Removal of Stuffing Box and Installation of Packing

NOTE: It is possible to change the packing in the stuffing box

without removing piping at this point in the disassembly
process. (See steps g, 14-18,22 and 23 as shown below)
However for complete inspection and maintenance of the
stuffina box comoonents the followina steos are aoorooriate.

1. Disconnect suction and discharge piping.

WARNING: If the pumpage is toxic, flammable, or corrosive

take Grocer orecautions.

2. Remove cylinder head (367) and cylinder head extension (368).

3. Remove plungers, unscrew plungers (353) from crosshead stubs

(122) and slide plungers through cylinder bore.

4. Remove the diagonally opposite outside discharge valve cover bolts

and install (2) eye bolts for lifting purposes

5. Attach hoist or chainfall and remove slack in lifting chains.

6. Remove the four cylinder tie stud nuts (two located on each side of the
power frame).

7. Carefully pUll the fluid cylinder away from the power frame.

WARNING: Pump components may be heavy, use proper

liftina devices to avoid oersonal iniurv.

Page 28
Unlan Pump Camp_ny Installation, Operation, and Maintenance Manual

CAUTION: In the face of the power frame on each side,

between the two cylinder tie stud holes, is a dowel pin. These
dowel pins align the fluid cylinder to the power frame. Use
caution to avoid damage to the pins in the power frame or the
aliqnment holes in the fluid cvlinder.

8. With the assembly on a suitable work surface remove the eight nuts
from the stud bolts which clamp the stuffing boxes (337) between the
flange (366) and the cylinder (300). The stuffing boxes may now be
removed.

9. Remove stuffing box gland (338) and follower (339) as well as the
packing.

10. The stuffing box throat busing (341) will remain in the cylinder (300).
The bushing is a press fit and may require tapping with a wooden
dowel to remove.

11. Wash the stuffing boxes and bushings thoroughly in a clean water
solvent.

12. Inspect surfaces of all parts. Any damaged or worn parts should be
replaced.

NOTE: Do not reuse worn plungers, packing, bushings or

stuffina boxes.

13. Install the throat bushing in the bottom of stuffing box.

I NOTE: See stuffing box layout drawing in final data package.

14. For "V" ring packing place male adapter ring in on top of throat
bushing. Place proper number of rings individually into stuffing box,
firmly seating each ring with fingers. Place female adapter ring into
stuffing box, then the follower bushing.

CAUTION: Care should be taken not to bend, tearorcut

rings as premature packing failure will result. "V" rings must
be installed with lips facing fluid cylinder (bottom of stuffing
box).

Page 29
Unlan Pump Camp.ny Installation, Operation, and Maintenance Manual

15. For square packing install proper number of rings individually into
stuffing box with joints staggered approximately 90 to 120 degrees
apart. Place follower bushing against last ring of packing.
16. Slide stuffing boxes into stuffing box flange plate.

17. Start the gland nut onto the threads of the stuffing box, but do not
tighten.

18. Gently work plunger through packing.

19 Install new gasket on stuffing box.

20. Install the complete assembly onto fluid cylinder. When reinstalling the
stuffing boxes the eight nuts which clamp the cylinder, stuffing boxes
and flange should be drawn up equally to insure that the stuffing boxes
bear evenly against the cylinder and the flange.

CAUTION: Be careful not to spring the flange by over

tightening the nuts. See torque requirements and values on
Chart #1 Section 4 Item B.

21. Reassemble fluid end assembly to power frame, connect plungers to

stubs and reinstall cylinder head & extension as described in fluid end
assembly. (Section 4, Item B)

NOTE: New gaskets should be installed each time the

cvlinder head has been loosened or removed.

22. Rotate the crankshaft by hand and while the plunger is moving toward
the fluid end, tighten gland nut by hand. "V' ring type chevron packing
is automatically sealed, meaning discharge pressure against the lips
provides the sealing effect.

CAUTION: High gland pressure is not required to assure a

seal. Pressure on the packing rings is only required to
eliminate gaps between them. Over-tightening the gland nut
may damage sealing lips and assure early packing failure
and plunqer wear.

23. For square packing the gland nut applies pressure to compress the
rings for sealing. The gland nut should be tightened only enough to
control excessive leakage. During operation slight leakage should

Page 30
Union Pump Com~ny
Installation, Operation, and Maintenance Manual

not be objected to as it will serve to lubricate the plunger and lengthen

the plunger and packing life, on both styles of packing.

The packing is now ready to be "seated in" by running the pump.

When the pump starts up and is running idle with little or no pressure
some leakage from packing may occur, this leakage normally will
subside as pressure is applied to the pump. The temperature of
plungers and stuffing boxes should be monitored (by touch) during the
seating in period. If excessive heating occurs, the stuffing box gland
nut should be backed off or loosened. Water may be squirted on
plungers occasionally outside of stuffing box during the seating in
period to further assure proper seating of the packing.

When readjusting the gland nut to compensate for wear and/or

excessive leakage, tighten the gland only as required to reduce
leakage to an acceptable level, making sure not to overtighten and
cause packing and plunger failure.

B. FLUID CYLINDER

Disassembly of Fluid Cylinder from Power Frame

The fluid cylinder may be removed from the power end as an assembly or
may be disassembled prior to removal. If removed as an assembly, step 6
can be deleted. If the fluid cylinder is disassembled while in position all of
the following steps apply.

1. Turn power off and lock in the off position.

WARNING: Be sure that the power to the motor is off and

locked out before beqinninq disassemblv orocedures.

2. Close suction and discharge gate valves.

3. Disconnect suction and discharge piping.

WARNING: If the pumpage is toxic, flammable, or corrosive

take orODer precautions.

4. Remove cylinder head (367) and cylinder head extension (368).

5. Remove plungers, unscrew plungers (353) from crosshead stubs

(122) and slide plungers through cylinder bore.

Page 31
Union Pump Comp.ny Installation, Operation, and Maintenance Manual

6. Remove discharge valve cover (317), discharge valve stops (370),

valve springs (335), and valves (321). Also remove suction valve
springs (334) and suction valves (320).

CAUTION: Valves have stamped numbers corresponding to

stamped numbers on the cylinder. Valves should be
reinstalled on their orooer oosition number.

7. Install two eye bolts in the diagonally opposite outside discharge valve
cover bolt holes.

8. Attach hoist or chainfall and remove slack in lifting chains.

9. Remove the four cylinder tie stud nuts (two located on each side of the
power frame).

10. Carefully pull the fluid cylinder away from the power frame.

CAUTION: In the face of the power frame on each side,

between the two cylinder tie stud holes, is a dowel pin. These
dowel pins align the fluid cylinder to the power frame. Use
caution to avoid damage to the pins in the power frame or the
aliqnment holes in the fluid cvlinder.

11. If stuffing box is to be removed and replaced follow instructions on

removal of stuffing boxes in Section 4, Item A

Assembly of Fluid End

Prior to reassembly, all mating surfaces must be clean and smooth. Paint,
dirt, and burrs must be removed from all mating surfaces to provide proper
alignment and sealing. Reassemble the fluid cylinder in the reverse order
from that described above for disassembly.

Fluid Cylinder Bolt Torquing

The following chart and diagrams list the proper torque values and torquing
sequence for fluid end bolting.

1. Torque Specifications

To avoid non-uniform gasket loading torque bolts to within -10% of the

listed torque requirement (see torque requirements on Chart #1) and

Page 32
Union Pump Comp_ny Installation, Operation, and Maintenance Manual

then repeating the sequence, tighten all bolts in the pattern to full
torque requirements. Stuffing box should be metal to metal contact
with the fluid cylinder.

WARNING: It is important to have all bolting torqued properly,

but it is most important to have the cylinder studs torqued to the
proper specification listed. If they are not, the tie studs may
break because of the high cyclic loading imposed on them.
Failure of these studs will result in separation of the fluid
cylinder from the power frame; a fracturing of the side of the
power frame, damage to plungers, stubs, stuffing box
comoonents, and oossible iniurv to personnel.

Page 33
Union Pump Camp_ny Installation, Operation, and Maintenance Manual

TORQUE REQUIREMENTS'
FOR TD-60 TRIPLEX AND TD-60SL PLUNGER PUMPS

RECOMMENDED
AREA PART THREAD SIZE TORQUE
(Lu bricated)
Ib-ft N-m
#7/8 FLUID Stuffing Box Flange 7/8-9 UNC 300 407
CYLINDER Cap Screw
Cylinder Tie Stud Nut 3/4-10 UNC 200 271
Discharge Valve Cover 7/8-9 UNC 300 407
Nut
Cylinder Head Nut 7/8-9 UNC 300 407
#1-1/8 FLUID Stuffing Box Flange 7/8-9 UNC 300 407
CYLINDER CaD Screw
Cvlinder Tie Stud Nut 7/8-9 UNC 300 407
Discharge Valve Cover 3/4-10 UNC 200 271
CaD Screw
#1-3/4 FLUID Stuffing Box Flange Nut 7/8-9 UNC 300 407
CYLINDER
Cvlinder Tie Stud Nut 3/4-10 UNC 200 271
Discharge Valve Cover 3/4-10 UNC 200 271
Nut
Cvlinder Head Nut 3/4-10 UNC 200 271
#2-1/2 Stuffing Box Flange Nut 7/8-9 UNC 300 407
FLUID
CYLINDER
Cvlinder Tie Stud Nut 3/4-10 UNC 200 271
Discharge Valve Cover 5/8-11 UNC 110 149
Nut
Cvlinder Head Nut 5/8-11 UNC 110 149

, APPLY TO STANDARD STEEL CONSTRUCTION.

CHART #1

Page 34
Union Pump Comp_ny Installation, Operation, and Maintenance Manual

C. VALVE ASSEMBLIES

General Description

The valves are a wing guided type as shown in the sectional drawing found in
the final data package. The valve seat is designed with an interference fit to
be shrunk into the fluid cylinder. Suction and discharge valve assemblies are
interchangeable but should be lapped to form proper mating sealing pairs.

Removal of Valves and Seats

The valves can be removed as follows

1. The discharge valves are removed by removing the discharge valve

cover nuts, discharge valve cover (317), and discharge valve stops
(370).

2. The suction valves are removed by removing the cylinder head (367)
and cylinder head extension (368).

CAUTION: It is necessary to use valve springs on suction

and discharge valves, replacement springs should be the
same as springs being replaced. The usage of improper
sorinos will cause erratic Dump ooeration.

3. Should it become necessary to remove valve seats, they can be

removed using a puller device consisting of a threaded rod, a collar,
washers, nut and a draw bracket. To remove the discharge valve
seats, install the threaded rod into the collar through the discharge
seat, place the draw bracket over the top of fluid cylinder and
threaded rod. Start the draw screw nut and thread it down to the draw
bracket. Tightening this nut will apply tension to the draw screw and
remove the valve seat from the fluid cylinder. (See Figure #2) Follow
the same procedure for the suction valve seats except as the seats
are pulled loose they are removed through the cylinder bore.

Page 35

, .
Union Pump Comp.ny Installation, Operation, and Maintenance Manual

DRA,*, SCRE,*,
DRA,*, SCRE,*, I-JUT

,*,ASHER

DRA,*, BRAUET

DRA,*, seRE,*, I-JUT

LOCATOR ROD NUT

LOCATOR ROD

FIGURE #2

Page 36
Union Pump CamP8"Y Installation, Operation, and Maintenance Manual

Inspection of Valve Parts

All valve parts should be inspected for wear and damage. Excessively worn
or eroded valves, valve seats, springs, and valve stops should be replaced.

Refinishing Valves and Seats

Seating surfaces of valves and seats will occasionally require refinishing; the
frequency depends on operating conditions and the liquid being pumped.
Abrasives or other foreign matter in the liquid will shorten valve life. If a
scratch, groove, or eroded area extends across the seating surface, the
surfaces must be refinished prior to reassembly. Refinishing is done by
lapping each value to the corresponding seat until a uniform seating surface
is obtained. For best results start with a coarse compound and use a fine
compound for final finishing. Under normal operating conditions very little
valve maintenance is required.

Installation of Valve Seats

Valve seats are a straight wall interference fit and can be installed as follows:

1. After cleaning all components and the machined bores in fluid

cylinder, make sure they are free of burrs and other contamination, the
valve seats can be installed by carefully placing it into seat bore and
placing a flat and smooth steel plate of suitable size that has no burrs
over the top of the valve seat and rapping it firmly with a hammer or
bar.

2. The discharge valves (321), springs (335), valve stops (370), and
covers (317) can now be installed.

NOTE: New gaskets should be installed each time cylinder

covers have been loosened and removed.

3. The cylinder head extension (368), serves as the stop for the suction
valve (320). Therefore, when installing the prong (stop) must be in a
downward position. The locating pin in the extension must engage in
the cylinder head (367) and the pin must be in an upward position.
Care must be taken when installing the cylinder head extension (368)
as not to cock the suction valve spring (334). When installing the
cylinder head extension "tilting" it will facilitate the installation and aid
in not cocking the suction valve spring.
D. POWER END

Page 37
UnlDn Pump Comp.ny Installation, Operation, and Maintenance Manual

1. In order to completely dismantle the power frame (100), the coupling

or sheave must be removed from the crankshaft.

WARNING: Before beginning the disassembly of any

moving parts, make sure the power to the motor is turned off
and locked in the off osition.

2. Drain the oil from the crankcase.

3. The plungers (353) will have to be removed. Follow the same

procedure as described in the fluid end disassembly Section 4, Item
B.

4. Remove crosshead stub deflectors (123), crosshead stub seal caps

(141), and crankcase cover (154).

5. Disconnect connecting rods (112) from the crankshaft (103) by

removing the connecting rod bolts (113) and rod bearings (116).
Then, push the connecting rod and crosshead assembly as far as
possible toward the fluid end.

CAUTION: Keep the bearing halves together with their

respective cap so they can be reassembled in the same position
if reused. When reassembling, match the set numbers (1,2,3,
etc.) stamped on the connectina rods and caps.

6. Remove the crankshaft frame end caps (132,133), keeping the shims
(134) intact with each cap for reassembly. The crankshaft (103) may
now be removed from either side by gently tapping on the crankshaft
using a block of wood to protect the crankshaft. (See Figure #3)

Figure #3 - Crankshaft Removal

WARNING: Pump components may be heavy. Use proper
liftina devices to avoid personal iniurv.

Page 38
Unlan Pump Camp_"W' Installation, Operation, and Maintenance Manual

7. Remove the connecting rod and crosshead assemblies. If the

crosshead assembly is to be reused, it must be reassembled in the
same crosshead bore that it was removed from.

8. Crosshead pin (119) is held in crosshead with two set screws.

Remove the set screws and lap out the pin. Crosshead pin bearing
(120) is a press fit in the connecting rod. When replacing be sure and
line up the hole in the crosshead pin bearing (120) with the hole in the
connecting rod. Also ream bearing to 1.5020/1.5025 inches.

9. Crosshead stub (122) is a press fit in the crosshead and pinned, and
machined with crosshead (117) attached to ensure alignment. If the
crosshead (117) or stub (122) is to be replaced, it must be done as
an assembly.

CAUTION: No attempt should be made to install a new stub

in a crosshead.

10. Main Bearings - Removal and Replacement

Main bearings are tapered roller bearing type. The outer race (cup) is
a slip fit in the power frame and may be removed by gently tapping the
crankshaft as described above in Step 6.

The inner race (cone) and roller assembly is installed with an

interference fit on the crankshaft and must be removed with a puller,
press or torch.

CAUTION: If a torch is used, care must be exercised not to

damage or overheat the crankshaft.

A new bearing must be installed as a unit, that is, a new

bearing cone should not be installed in an old race (cup) or
vice versa. To install a new bearing on the crankshaft, it is
recommended that the inner racelbearing assembly be
heated to 300°F (150°C), no hotter, and slipped over the
shaft. The outside cup is then placed over the bearing once
it has cooled and then assembled into the Dower frame.

11. Connecting Rod Bearings

Page 39
Union Pump Camp_"¥' Installation, Operation, and Maintenance Manual

The connecting rod bearings (116) (inserts) are made in two halves
and clamped into position between the connecting rod and cap. The
bearing is steel with a heavy layer of babbitt on the wearing surface.
Upon final assembly of the connecting rod (112), lubricate the threads
and heads of the bolts (113), then torque to the specified fUb. per
Chart #2.

12. Power End Torque Requirements

Torquing of the bolts on the power end is less critical than on the fluid
end, and is usually satisfactorily accomplished by an experienced
mechanic without the use of torque wrenches. For those who wish to
use torque wrenches, specific power end torque values are shown in
Chart #2.

13. Clearances

The following are the clearances when all parts are new.

Replace parts (or Adjust)

When Parts Are New When Clearance Exceeds:
Inch mm Inch mm
Crosshead (#117) in
Power Frame .004 - .007 .10-18 .011 .28
Crosshead pin (#119) in
crosshead .0005 - .0012 .013 - .03 002 .05
Connecting rod bearing
(#116) over crankshaft .005 -007 .13-.18 011 .28
Crosshead pin bearing
(#120) over pin 0020 -0024 .05 - .06 .005 .13

Reassembly of Power End

Reassemble power end in reverse order. It is a good practice to install new

oil seals (630) and (632) as well as new gaskets (620 and (623).

CAUTION: Care should be taken in tightening the plunger

(353) to the crosshead stub (122), as it should not be
overtiahtened.

Review the lubrication plate on the pump or see Section 3, Item 82 for the
proper lubricating oil for the crankcase. The crankshaft rotation should be
checked as proper rotation is essential for lubrication of the power end
components.

Page 40
Unkln Pump camp_...,. Installation, Operation, and Maintenance Manual

1. Crankshaft End Play

When the pump is built, the crankshaft end play is set at 0.001" (0.03
mm) to 0.003 (0.12 mm). Only when replacing a crankshaft or a main
bearing does this end play need to be reset to these limits.

A good method of measuring end play is by mounting a dial indicator

on power frame and placing indicator button on any vertical surface of
crankshaft. The crankshaft is then pried to one side, and then the
other, noting the total travel of the dial indicator. To establish proper
end play, add or remove shims at crankshaft frame caps.

Crankshaft
End Play Adjustment

When shimming is complete, connecting rods and pin bearings

should be positioned near center of crosshead opening. If any pin
bearing rubs on inside of any crosshead, transfer shims from one side
of pump to other to shift crankshaft.

Page 41

, ,
Union Pump Camp_"., Installation, Operation, and Maintenance Manual

'>~crv::{ ';'_r "

rfb';:;' ii ~ ::," •

Centering Connecting Rod in Crosshead

Page 42
 Unlan Pump camp_.,., Installation, Operation, and Maintenance Manual

TORQUE REQUIREMENTS'
FOR TO-60 TRIPLEX AND TD-60SL PLUNGER PUMPS

RECOMMENDED
AREA PART THREAD SIZE TORQUE
(Lubricated)
Ib-ft N-m
TD-60 Connecting Rod Bolt 1/2-20 UNF 40 54
POWER END
Frame CaD Caoscrew 1/2-13 UNC 35 47
Crankcase Cover Cap 3/8-16 UNC 15 20
Screw
Stub Seal CaD Screw 1/2-13 UNC 35 47
Crosshead Pin Set 3/8-16 UNC 15 20
Screw
Plunoer-To-Stub 9/16-12 UNC 40 54
Plunoer-To-Stub 3/4-10 UNC 75 102

• APPLY TO STANDARD CONSTRUCTION.

CHART #2

Page 43

, '
 PAGE
INTENTIONALLY LEFT
BLANK
A Textron Company
Installation, Operation, and Maintenance Manual

Warranty
The Company warrants that its products are free from defects in material and
workmanship and will have the capacities and ratings described in the Company's
proposal as accepted. The terms of this warranty shall be for a period of one (1)
year after the product is placed in service but not exceeding eighteen (18) months
after shipment. The Company agrees to repair or replace, f.o.b. shipping point, any
goods or parts thereof which during the term of the warranty are proven to violate
the above warranty to an extent which would affect the reliable operation of the
goods The Company's accepted method of testing shall be determinative of the
existence of any such defect. The warranty is effecflve only if Buyer promptly
notifies the Company in writing of the defect. and promptly delivers the defective
goods or parts to the factory, delivery prepaid Liability for damage caused by such
defective goods or parts shall be limited to repairing or replacing the defective
goods or parts as aforesaid. This warranty shall not apply to goods which have
been altered or repaired without the Company's written consent. This warranty
remains in effect only if the products are used in accordance with instructions in
manuals and instruction sheets furnished by the Company with regard to
installation, maintenance, start-up and safety. This warranty shall not be effective if
Buyer fails to adequately protect the goods from adverse environmental conditions
before and after start-up and to act in accordance with instructions furnished by
the Company.

NO WARRANTY IS MADE AGAINST CORROSION. THIS WARRANTY IS

EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR IMPLIED,
WHETHER OF MERCHANTABILITY OR OTHERWISE. WHICH IS NOT
DESCRIBED IN THE FACE HEREOF, AND NO OTHER REPRESENTATIONS
OR AFFIRMATIONS OF THE COMPANY, WHETHER BY WORDS OR ACTS
SHALL CONSTITUTE A WARRANTY.

UNION PUMP COMPANY

BATILE CREEK, MICHIGAN, U.S.A.

42
 Maintenance Record
Date Work Performed
I!Jl!Il!mI Pump
A Textron Company
Installation, Operation, and Maintenance Manual

To maintain peak pump performance .. .

Insist on genuine Union Pump parts
Swift service from facilities in
UNITED STATES CANADA

Midwest Service Center Burlington Service Center

Union Pump Company Union Pump Canada Limited
4600 West Dickman Road 4211 Mainway Drive
Battle Creek, M149015-1098 Burlington, Ontario L7L 5N9
269-966-4600 Phone Canada
269-966-4644 Fax 905-315-3800 Phone
905-336-2693 Fdx
Southeast Service Center
Union Pump Company Calgary Service Center
12742 Ronaldson Road Union Pump Canada Limited
Baton Rouge, LA 70807 3525 62nd Avenue SE
225-775-2660 Phone Calgary, Alberta, T2C 1P5
225-774-7555 Fax Canada
403-236-8725 Phone
Southwest Service Center 403-236-7224 Fax
Union Pump Company
10723 Rockley Road Edmonton Service Center
Houston, TX 77099 Union Pumr Canada Limited
281-933-2900 Phone 11516184t St. NW
281-933-6434 Fax Edmonton, Alberta, T5S 2W7
Canada
Western Coast Service Center 780-489-2258 Phone
Union Pump Company 780-489-2284 Fax
9838 Firestone Blvd.
Downey, CA 90241 UNITED KINGDOM
562-622-2380 Phone
562-622-2385 Fax Union Pump UK Service Center
Union Pump a trading division of
East Coast Service Center David Brown Engineering Limited
Rotating Technology Services, Inc. Green Road
An Authorized Field Service Penistone, Sheffield, UK S36 6BJ
Representative of the Union Pump Co. +44 (0) 1226 763 311 Phone
177 Mikron Road +44 (0) 1226766535 Fax
Bethlehem, PA 18020
610-746-4571 Phone FRANCE
610-746-5907 Fax
Union Pump France Service Center
Service Support 24/7: Union Pump SAS.
+1 (269) 966-4664 39, Avenue du Pont de Tasset
US - 1-800-877-PUMP B.P. 435-74020 Annecy Cedex
UK - +44 (0) 1 226222200 France
CANADA 1-905-315-3800 +33 (0) 4 50 05 5600 Phone
EU - +33 (0) 4 50 05 5600 +33 (0) 4 50055880 Fax

For more information visit our website at: http://www.unionpump.com