GARDNER DENVER

MODEL PJ8

SINGLE ACTING

PJ-400June, 1968

TRIPLEX PUMP

WARRANTY

Subject to the terms and conditions hereinafter set forth, Gardner-Denver Company (theCOmpany) warrants products and arts sold by it, insofar as they are of its own manufacture,against defects of material and worKmanship, under use and service in accordance with Companyswritten instructions, recommendations and ratings for installation, operating, maintenance andservice of products, for a period of three months from the date of initial use, provided that suchthree month period shall in no case extend beyond one year from the date of shipment byCompany. THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT, ASCOMPANY MAY ELECT, OF ANY DEFECTIVE PARTS, REGARDING WHICH, UPONDISCOVERY OF THE DEFECTS, THE PURCHASER HAS GIVEN IMMEDIATE WRITTENNOTICE. Installation and transportation costs are not included. Company shall have the optionof requiring the return to it of the defective material, transportation prepaid, for inspection,Because of varying conditions of installation and operation, all guarantees of performance aresubject to variation of 370. COMPANY DOES NOT WARRANT THE MERCHANTABILITYOF ITS PRODUCTS AND DOES NOT MAKE ANY WARRANTY, EXPRESS OR IMPLIED,OTHER THAN THE WARRANTY CONTAINED HEREIN, Company has not authorizedanybody to make any representation or warranty other than the warranty contained herein.

TABLE OF CONTENTS

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suction Line.....,....,.. . . . . . . . . . . . . . .Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . .Surge Chamber, . . . . . . . . . . . . . . . . . . . . . . . . .Starting A New Pump ...,.... . . . . . . . . . . . . .Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filte r . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . .Direction of Rotation . . . . . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . . . . . . . . . . . . ..OSizes and Ratings Chart ...,..., . . . . . . . . . . . .

SERVICE INSTRUCTIONS POWER END . . . . .Jackshaft . . . . . . . . . . . . . . . . . . . . . . .,, .,,..Connecting Rods..........,.. . . . . . . . . . . . .Eccentric and Bearing Assembly . . . . . . . . . . . . . .Main Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22223333444

55667

PJ-400

Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crossheads and Pins . . . . . . . . . . . . . . . . . . . . . . .Oil Stop Heads . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS FLUID END . . . . . .Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stuffing Boxes and Liners . . . . . . . . . . . . . . . . . .Pistons- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .piston washing system, . . . . . . . . . . . . . . . . . . . .Maintenance of Valves,.,,.. . . . . . . . . . . . . . . .BNChargingP ump. ,. .,.... . . . . . . . . . . . .Bearings (Charging Pump) ...,...,. . . . . . . . . . .Belt Drive (Charging Pump) . . . . . . . . . . . . . . . . . .Recommended Running Clearances . . . . . . , . . . . .Manufacturing Fits . . . . . . . . . . . . . . . . . . . . . . . .Recommended Torques . . . . . . . . . . . . . . . . . . .

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10101011111111

INSTRUCTION AND SERVICE MANUAL

FOR PJ8 SINGLE ACTING TYPE POWER PUMP

FOR MUD SERviCE

Reference to Parts List covering the model pump being serviced is recommended in con-nection with this Instruction Book.

Repair Parts Lists with Sectional Views are available from any Gardner-Denver Companysales office listed on the back cover. When ordering parts, alwa s give size and serial number

fof the pump. Always use genuine Gardner-Denver parts. For e ficient factory-trained service,consult a Gardner-Denver Service Specialist.

When working on any pump, be certain there is no fluid pressure on either suction or dischargeside. Pressure on fluid end might move pum

band cause damage or injury to personnel. It is

recommended that all suction valve covers e removed to avoid fluid pressure building upagainst pistons or plungers.

If drive is not to be removed, it is recommended that air line to clutch be disconnected toprevent accidental starting of pump.

1. LOCATION

The pump should be set level and solidly supported. The drive should be accurately aligned. Pump should be placed as closeto the slush pit as possible to keep the suction line short and direct. Locate ump as low as possible to maintain a minimumsuction lift to the centrifugal charging pump which is used because of the highspeed of this type of mud pump.

2. SUCTION LINE

Suction pipe or hose should be the full size of the suction opening on the chargin pump. If for any reason the suction lineis of greater length than usual, the next larger size should be used. Suction line s ould slope up toward the charging pumpat uniform grade to prevent air pockets being formed. Suction line must be absolutely tight as any air leaking into theline will reduce the ca acity of the pump and cause a hydraulic hammer or knock. If it is necessary to have bends in thesuction line they should have long radius sweeps and be kept to a minimum in quantity. Sharp right angle bends in suctionline must be avoided. poor suction conditions are responsible for almost all fluid end noise due to partial filling of thecylinders.

Suction line should be supported near centrifugal charging pump to keep strain from breaking the casing at the suctionflange.

At least one section of hose in the suction line is desirable to isolate pulsations or vibration. Total suction line should beas ahort as installation condition permits. THIS IS IMPORTANT.

A suction strainer is recommended for the suction line of every pump. It must be checked frequently and cleaned when-ever necessary. No strainer is furnished with this pump.

It is recommended that a 50 PSI auge with a needle valve for protection be installed in the tapped hole in the side of thecharging pump. This gauge will in cate if pump is charging or if suction valves are not working properly.

3. RELIEF VALVES

A relief valve set at 50 to 100 PSI placed in the line between the centrifugal charging pump and the mud pump suctionmanifold will alleviate excess line pressure in case of faulty suction valves in the mud pump.

The pump should be protected from excess discharge pressure by a 2 shear type relief valve. This valve should be installedin a vertical position in a tee in the discharge line as close to the pump cylinder as possible. Never install a shutoff valve inthe line between the relief safety valve and the pump discharge manifold. If more than one pump is used, a pressure reliefvalve should be furnished for each pump.

A hand operated pressure release valve should be installed in the discharge line following shear relief valve, with dischargeline leading to mud tank. This valve is used to bleed air from discharge line in starting. It is also used to relieve pressurein starting more than one pump in parallel.

4. SURGE CHAMBER

A surge chamber is not essential with this type pump; however, one may be used for additional protection to surface equip-ment or to reduce pulsations when pumping gaseous mud. If a surge chamber is used it is recommended that it be of a

PJ-400 Page 2

nitrogen charged pressure bag type. The surge chamber must be kept properly charged, as instructed by the manufacturer.

The multiple cylinders and high speed result in a very smooth discharge flow. This is of particular advantage when operatingat high pressure with the smaller size drill pipe.

5. STARTING A NEW PUMP

It is necessary that drive be arranged to turn the pump in the direction indicated by arrow on the sectional view in thisbook, on outline prints, and cast on pump frame. This provides for crosshead load to be carried on the lower slide. Thismeans better Lubrication and quiet operation. Pump must run in indicated direction because lube oil pump used to forceoil through lubrication system will pump in one direction only.

Pumps are shipped from the factory without oil in the crankcase. The hood should be removed and the power end ex-amined and cleaned if necessary. The pump may have been in storage or in the yard for some time, and as a-consequence,water may have condensed in the crankcase. Drain all water accumulated in the bottom of the crankcase. Fill crankcasewith oil of proper grade to the proper level.

All nuts and cap screws should be checked for tightness.

It is recommended that fluid end of the pump be primed to prevent excessive wear on the fluid pistons and Iiners whenstarting. PRIMING IS IMPORTANT! IT LUBRICATES PISTONS IN LINERS.

Pump should be started slowly but not run below half of rated speed. Recheck oil level as it may be necessary to add a smallquantit of oil to compensate for that adhering to the walls of the crankcase and the moving parts. The pump may then be

gradually broughtup to full speed and full working pressure. Watch for undue heating or abnormal noise in the working parts.

Check all joints in the suction line to be sure there are no air leaks.

6. LUBRICATION

All power end working parts are lubricated by oil in the crankcase. Check oil level frequently.

Selection of oil is to be taken from the recommendations given on the pump nameplate. Local conditions and ractice mayalso influence the selection. Essential additives are foam and oxidation inhibitors. Oil is to be added as require to maintainoil level near top of oil level indicator on the side of the frame.

Oil is constantly circulated through a renewable element falter and then through a heat exchanger bydriven from one main gear. Oil from heat exchanger is introduced into eccentric shaft to lubricatethrough drilled passages to both connecting rod bearings, under force feed.

Operating temperatures of the oil should be kept below 1700 F. to reduce oxidation.

means of a rotary pumpmain bearings. Oil flows

Time between oil changes depends upon local and/or operating conditions. Under normal circumstances, if the crankcaseis ke t clean, it should not be necessary to change oil more than once in 1000 hours of operation. Many operators change

foil a ter each well drilled. Oil should be changed if found to be dirty or contaminated with mud or water. This is especiallyimportant for the PJ8 pum , as the oil lubricated roller bearings will be dama ed by contamination. an oil change is com-paratively inexpensive h, as t e crankcase holds approximately 30 gallons. Goo d oil is much cheaper than damaged parts.

in order to assure proper Lubrication the pump should not be run under 60 RPM for more than a few minutes at a time.

The oils normally used in mud pumps are quite viscous at lower temperatures. When starting cold, the pump should bebrought Up to operating speed slowly. This practice will assure proper lubrication of all working parts before pump is fullyloaded.

7. OIL FILTER

A re laceable element oil filter is located inside the pump crankcase. Filter mounting flange is on the outside, making itpossible to replace the element by removing end plate. only the oil within the falter case will be spilled when elementis withdrawn.

Filter element should be replaced each time crankcase oil is changed or every 1000 hours of operation.

Filter element is protected from excessive internal oil pressure by a relief valve between it and the oil pump. Relief valvesetting is 110 PSI.

Oil flows through the oil falter before going through the heat exchanger.

8. HEAT EXCHANGER

A bronze heat exchanger is provided to keep crankcase oil temperature at 160 F. by means of an automatic water control

PJ-400 Page 3

valve. This valve has a heat sensing probe in the crankcase oil, and it monitors water to the heat exchanger to maintain oiltemperature within close limits.

Water must be drained from the heat exchanger during freezing weather. Ruptured water tubes will admit water into the oil,with resulting damage to the working parts of the pump.

Cooling water can be drained from the heat exchanger by removing water connections and blowing compressed air into

UPPer opening. Water Will then flOW from the lower opening. air is necessary as water will not otherwise drain due tosmall size of tubes, capillary attraction, and the horizontal position of the heat exchange mounting.

Water should not be admitted to the heat exchanger as long as oil temperatures do not exceed 160 F. A dial thermometeris standard equipment on the PJ8 pump.

Fresh or salt water can be used for cooling. Zinc anode plugs are provided for corrosion protection. These plugs are to bereplaced when they have been eaten away.

9. DIRECTION OF ROTATION

The PJ8 pump is to be driven in one direction only as shown by arrow on pump outline, Figure 3, and cast on pump frame.The oil pump which forces crankcase oil through the falter and heat exchanger is a nonreversible pump.

Running pump in the prescribed direction will also result in proper lubrication and quiet operation as load on crossheadwill be carried on lower slide.

10. OPERAtiON

For normal drilling operation, the pump is to be run at the ratings listed in the following table. In no case should pressureexceed that shown for each diameter piston to do so would subiect working arts to operating loads in excess of thosefor which they were designed, resulting in reduced life.

. . .

SIZES AND RATINGS

MODEL PJ8 275 HP TRIPLEX MUD PUMP

Cylinder

Diameter

5

41/2

4

3-1/2

3-1/4

3

Stroke

8

8

8

8

8

8

Displacement

GPR

2.04

1.65

1.31

1.00

.862

.734

GPM

357

289

228

175

151

128

Max.Pressure

PSI

1122

1386

1753

2290

2657

3118

PistonLoad

22,030

22,030

22,030

22,030

22,030

22,030

PumpRPM

175

175

175

175

175

175

Weight Complete Pump, Dry = 8,610 PoundsGear Ratio = 4.7 to 1

JackshaftRPM

823

823

823

823

823

823

InputHP

275

275

275

275

275

275

Overall Length Over Skid = 107-1/2Overall Width Over Jackshaft = 66-3/4Overall Height = 49-1/2

PJ-400 Page 4

SERVICE INSTRUCTIONS

POWER END

Remove hood and crosshead inspection plates for access to working parts. Before working in inside of crankcase, it is neces-sary to drain the oil. Oil pump mounting and piping connections are below the oil level.

Mark all parts during dismantling so they can be returned to their original position during assembly.

11. JACKSHAFT

It is advisable to remove eccentric and gear assembly beforeattempting to remove the jackshaft. Jackshaft bearings will notclear the gears.

Remove all sheaves or other drive members from the jackshaft.SUpport each end of shaft during removal,

Remove bearing retainer from inner end of bearing housing. Re-move bearing end plate from each side of the pump. Removebearing housing from one side and pull jackshaft and bearingassembly through this opening. opposite bearing housing need notbe removed from the frame.

Jackshaft bearings are of the double spherical type with end thrustin both directions taken on the right hand bearing, Both bearingsare identical.

The safest way to remove the bearings from the jackshaft is by thecareful use of heat. Do not overheat to the point where bearingis discolored.

I RIng for L0caTlN63t BFIUBEarinG ONU,M-Hn

+ ~, ha~ JRCKSHRFT

I 1, I I 1-

FIGURE 1.

When replacing jackshaft bearings it is necessary to make a split disc to clamp on shaft and against inner face of the outerbearing race to hold race square with axis of bearing. See detail in Figure 1,

The jackshaft bearings should be replaced if any of the rollers or races show damage or if they are excessively worn. A noisybearing indicates bearing damage, requiring replacement. Check clearances by inserting feeler gauge between the roller andinner race with bearing assembled on the shaft and in the housing. This check can be made with the bearing assembledout of the pump. See recommended running clearances on page 11,

To mount new bearings, install split disc (Figure 1) on shaft as shown in Figure 2. Heat bearin in oil to about 300 F. andslip it on the shaft against the bearing shoulder and split disc. The shaft can then be reinstalled in the frame, followed bythe eccentric assembly.

FIGURE 2. JACKSHAFT BEARING INSTALLATION

PJ-400 Page 5

To reassemble the jackshaft in the pump, it is necessary to reverse the procedure of removal. The teeth of the pinion canmesh in only one direction, therefore, the jackshaft is not interchangeable end for end in the pump unless gear andeccentric assembly is also reversed. Reversal of the complete gear set is permissible after gear or pinion teeth becomebadly worn. When gear set is reversed it is necessary to install a new oil pump drive pinion to match the opposite spiralmain gear.

Recommended direction ofrotation,on or the pump provides that outer ends of gear and pinion teeth lead. This means thatwhen viewing from the hood opening, the outer ends of the gear teeth point upward toward the jackshaft and the outerends of the pinion teeth point toward the gear. Gears may be reversed, but direction of rotation of the pump MUST NOTBE REVERSED. Pump must be run in the direction shown on sectional view and indicated by arrow on outline printand frame. Inner ends of teeth will lead after gear set has been reversed.

After jackshaft is in place with the pinion in mesh with the gear, install the bearing housings. The housing is to be startedon the bearing and in the bore of the frame and lightly driven in. Be careful to keep dirt from bearings during assembly.Be sure the gasket is on the housing. Long threaded studs may be used to pull the housing into the frame bore, It is wellto work both housings at the same time after they have been well started over the bearing outer race. This will minimizeend thrust on the gear teeth. permanently bolt jackshaft bearing housings and remove the split discs used for positioningbearings during assembly. When discs are removed, install the bearing inner retainer, with cap screws and locking wire, onthe right hand side of pump only.

The outer grease seals are to be laced in the bearing end plates after they are bolted to the bearing housings and frame.Coat inside of the oil seals liberlly with bearing grease. Each outer seal is to be installed with garter spring to inside, towardbearing Seal bears on a replaceable wear sleeve shrunk onto shaft to prevent wear under the seal.

12. CONNECTING RODS

The connecting rods are split and bolted together on shims used principally to absorb normal factory manufacturing toler-ances. If the eccentric assembly is to be removed from the frame, the connecting rods need not be unbolted. In this casethe crosshead pins must be removed, Eccentric and rod assembly will lift out of the frame freely if left hand eccentric ispositioned directly above the shaft.

Whether or not the connecting rods need be removed depends upon the nature of work being done on the pump.

Connecting rod caps can be removed in case it is desired to remove eccentric assembly only in order to replace main bearings.

The connectin rods are provided with high lead bronze liners which bear against the eccentric. The liners are recision madealJ bEin identical are secured by clamps held to the connecting rod and cap by cap screws. They careplaced by

removing connecting rod caps, but without removing connecting rod body from the pump.

The shims between connecting rods and their caps can be used to adjust liner to eccentric running clearance to a limiteddegree. In no instance should an adjustment exceeding .006 be attempted by this means. The condemnable limit for thisbearing is so high that replacement of the liners is preferable to the limited adjustment the shims provide.

The bore in the liner is not round, but a compound bore designed to give maximum bearing surface. Field shop reboring ofthe liners is not recommended for this reason.

Connectin rods are drilled to conduct oil under pressure to crosshead pin bushings. These bushings are bored to size afterthey are Factory assembled. When installing repair bushings it may be necessary to hone to proper running fit over thecrosshead pins as shown in table on page 11.

13. ECCENTRIC AND BEARING ASSEMBLY

IMPORTANT Be sure to remove oil pump drive pinion when removing or replacing eccentric and gear assembly to avoidbending oil pump shaft when gear is moved.

Eccentric runs on two double row spherical roller bearings supported by the stationary main shaft.

To remove the eccentric and gear assembly, remove hood, and remove the connecting rod caps. Be sure caps are markedso they can be replaced in their original position. Keep shims in their original position.

Remove clamps that hold the main, or eccentric shaft totheir original position.

Lift the eccentric assembly from the frame. Remove thedrive the shaft out with a block of wood and a hammer.

frame. Be sure clamps are identified so they can be returned to

main bearing retainer plates from each end of the eccentric and

Bearings are a slip fit on the shaft and a light press fit in the bearing bore in the eccentric.

Bearings are to be replaced if worn excessively or if damaged. A damaged bearing will be noisy. Do not remove protectiveGReasein new bearings. It will not contaminate the crankcase oil.

PJ-400 Page 6

When new bearings are to be installed be sure to replace the rubber quad ring seals inside the bronze seal retainers pressedinto the eccentric bore just inside the eccentric bearings. These seals bear on the shaft and prevent loss of oil pressure tothe eccentric cams and connecting rods.

14. MAIN GEARS

After long wear the main gears can be reversed by changing eccentric and gear assembly end for end, or by exchanging thegears on the eccentric, In either case it is also necessary to change the jackshaft end for end. When gear set is reversed it isnecessary to install a new oil pump drive pinion to match the opposite spiral main gear. It is not possible to move the oilpump to opposite side of the frame in this pump.

In a new pump the gears are mounted so the outer ends of the teeth lead. If gears are reversed, the outer ends of the teethwill follow.

Gears are located on the eccentric flange by means of one cap screw which is larger than the rest. It should be inserted fIRst,and all cap screws tightened evenly and wired in pairs.

Lower the eccentric assembly, with main shaft installed, into the frame after jackshaft has been installed. Secure shaft toframe with clamps. See torque table on page 11 for proper tightening of the clamp stud nuts.

Reassemble connecting rod caps in original positions. Be sure original shims are in place. See table on page 11 for tighteningof the connecting rod bolt nuts.

Check crankcase for tools or other parts and fILLwith new oil before replacing hood.

15. PUSH RODS

push rods can be removed from the crossheads by workin through handhole plates in the sides of the frame and also throughthe oil stop openings after the oil stop head assemblies ave been removed.

Be careful not to damage the highly polished surface on which oil seals bear.

Push rods are chrome plated and should be protected when the pump is painted. Paint will damage the oil stop headseals.

16. CROSSHEADS AND PINS

Crossheads are of one-piece construction without removable shoes. They bear on slides bored in the frame.

Crossheads are equipped with straight fill-floating pins secured each end by spring retainers in grooves near the ends.

The retainer rings can be reached from the main hood opening or through the crosshead ins ection lates on the sides of$the frame, It will be necessary to turn the pump over to locate each crosshead for accessiblity wh e removing the cross-

head pins.

Crossheads may be removed by removing oil stop heads, push rods and crosshead pins. Slide the crosshead through the oilstop bore in the frame and lift them clear. Be careful to protect the shoe surfaces from damage. Also protect the lowerslide in the frame by placing a wooden block beneath the small end of the connecting rod.

It is necessary to remove one outer crosshead before the center one cars be reached for removal.

17. OIL STOP HEADS

Oil stop heads keep crankcase oil within the frame. They also keep mud and liner washing water from entering the crankcase.

Oil stop packing consists of two identical urethane seals mounted in adaptors. They are not adjustable.

The inner seal lip is pointed inward toward the crankcase to strip oil from the push rod. The outer seal lip points outwardtoward liner to strip mud and/or water from the push rod. Be certain seals are properly located.

The seal adaptors, with seals in them, can be slipped off and on the push rods by removing the clamp holding piston rodsagainst the push rods and separating the two flanges. DO NOT use a screwdriver or drift to separate the push rod and pistonrod flanges. Turn the pump slightly.

It is essential that oil stop head seals be replaced at the frost indication of leakage. Oil leakage will be indicated by oil col-lecting on top of the liner washing water in the reservoir. If rig water is used for washing and run to a waste area, it is difficultto check by above method.

If oil leakage is serious it will show u in a lower oil level in the crankcase. In this case oil must be added to crankcase asrequired, until new oil stop seals can be installed.

PJ-400 Page 7

Leakage of mud and water into the crankcase will be indicated by a milky appearance of the crankcase oil. If excessive,the mud can be detected by reaching through the oil with the hand, or by draining out a small quantity of oil. Mud willalso be seen below oil stop heads on inside of crankcase through crosshead inspection plate openings.

When mud is found in crankcase, oil should be changed. Drain and clean out crankcase before putting in the new oil. Re-place mud scraper seals in oil stop heads before running pump.

We recommend oil stop head seals be changed every six months of operation, even though leakage is not evident.

OIL HEAT EXCHANGER J L ROD WASH PUMP B74257

FIGURE 3. MODEL PJ8 PUMP OUTLINE

PJ-400 Page 8

FLUID END

18. CYLINDER

The PJ8 pump is equipped with a one-piece alloy cast steel cylinder.

Cylinder is secured to the frame by high tensile strength connecting studs. It is important that nuts on these studs be checkedoccasionally for tightness. A loose nut will cause a stud to break under pulsating load. See proper tightening torque on page 11.

The connecting studs extend through the stuffing box flanges to clamp the stuffing boxes and liners tightly against the faceof the cylinder,

19. STUFFING BOXES AND LINERS

When stuffing boxes are reinstalled or replaced, it is advisable to check cylinder to frame stud nuts and tighten if necessary.Refer to table on page 11 showing proper tightening torques.

Nuts holding stuffing boxes in place should not be overtightened as distortion of the stuffing box and liner bore may result.Recommended tightening torque is shown in table on page 11.

Change size of pistons and liners as volume and/or pressure requirements change. See rating chart on page 4.

Liners are replaced by removing the stuffing boxes. They should be cleaned and oiled after removal to protect againstrusting during storage, so they can be used again if they are in usable condition.

pump liners are to be clean both inside and out when installed. Also clean the stuffing box bore and lightly oil all surfaces.

Use new gaskets when installing liners and be sure to clean all surfaces against which the gaskets fit. Liners or valve chambersmay be cut by leaking gaskets. If pistons are properly maintained there will be little or no cutting of the liners.

20. PISTONS

Single-acting pistons are made up of special body fitted with a special piston insert developed for these single-acting pumps.Insert snaps into a groove in body. It is necessary to cut the piston insert off the piston body when replacement is required.piston bodies 3-1/4 and smaller are integral with the piston rod.

pistons, with piston rods, can be removed or installed through suction valve opening after valve upper guide is removed byturning it 90 . Valve spring must also be removed.

It is recommended that a piston and rod assembly be kept ready for replacement. This is a practical time saver.

21. PISTON ROD

Piston rods are manufactured of high carbon steel. They are electrolytically plated to protect against corrosion. They areprovided with a knurled section so rod can be held while tightening piston nut. It is important that piston rod nut be tightenedto recommended torque shown on page 11.

Piston rod to piston fit is straight. piston fits against flange on piston rod with an O ring gasket to prevent leakamoval of piston is a simple operation since it is not driven on a taper. Keep piston rod to push rod clamps tight at all timesto prevent damage to their connecting flanges and pilots. DO NOT use a screwdriver or cold chisel to separate the flanges.Turn the pump slightly or use a puller screwed onto piston rod threads where they extend beyond piston nut.

22. PISTON WASHING SYSTEM

The piston washing system is vital to the satisfactory performance and life of pistons and liners. The complete s stem mustbe kept in good operating condition. Washing fluid should be maintained in good condition and should bereplaced whencontaminated to the point where free circulation is impaired. This is of utmost importance and should be impressed uponall operators of the pump.

Water su ply lines should be permanently attached to the openings provided in the circulating pump suction lines betweenthe circu atin pump and the tank. Water is then quickly available as a washing fluid or to flush out the lines by operating

the proper valves in the piping system.

The piston washing fluid may be varied according to conditions and operators reference. Water makes a suitable washingfluid under most conditions. Good results can be obtained using water with one-half gallon of soluable oil per tank of waterwithin the closed system. A light oil gives good results under some conditions, and can be used under severe freezing con-ditions.

PJ-400 Page 9

The more fluid circulated, the better; however, it should be regulated by a valve in discharge line of the centrifugal circulatingpump to prevent splashing and being blown about by the wind. Besides making things messy and wasting washing fluid, thiscould result in dangerous conditions around the pump when using any of the oil based solutions.

23. MAINTENANCE OF VALVES

In order to keep the pump in its best operating condition, it is necessary to examinethe suction and discharge valves occasionally to see that excessive wear or cuttingby the slush or mud has not impaired their efficiency. any worn or damaged partsshould be replaced,

This is especially true with regard to the inserts. Standard inserts are made fromurethane and are the part of the valve which should be changed most frequently.They are much cheaper than the valves and seats, and if inserts are renewed as soonas they begin to fail, the more expensive steel parts will last much longer. Routineinspection of valves every two or three days is recommended.

When removing a worn valve seat, use the Gardner-Denver puller powered by ahydraulic jack, Be careful to chain or tie the jack down as itwill Jump violently whenvalve seat lets go. If it becomes necessary to resort to use of heat or a cutting torch toremove a valve seat, the services of a man experienced in this operation is necessary,

Before putting new seats in the pump, the tapered bore in the valve seat deck ofthe cylinder must be thoroughly cleaned with a wire brush. Wire brush should beused around the bore rather than up and down, Wipe the bore clean and do notuse oil or grease. The bore must be clean and dry or seat may not seat properly.

Place the new seat in the bore. Use an old valve bumper or a block of hard woodand drive with a sledge to a snug initial fit. The pressure load on the valve inoperation will drive the seat home. Never reuse an old seat once it has been re-moved from a cylinder, as it may not fit solidly in the valve deck. FIGURE 4. VALVE SEAT

PULLERReplace the upper valve guide if worn. Replace the valve spring if it is worn,corroded, distorted, or below normal tension. Valves are provided with stainlesssteel springs for maximum operating life. A broken spring will cause ra id wear of valve guides and should be replaced. Itwill also cause wear on suction valve guide mounting lugs inside the cylinder.

Do nut put a used valve assembly on a new seat unless it is in practically a new condition. Be sure to replace a doubtfulinsert to protect seat and bumper.

It requires experience and judgement to determine if valve parts should be replaced or not. Valves are cheaper than down time.

When installing valves put the gasket carefully in place in the valve chamber and installed.cover plate. Be sure gasket is nottwisted or extruded. Tighten valve cover lock securely by using a bar and hammer. See sectional view for proper assembly.

The life of the valves will be lengthened if the mud tanks are kept clean. Foreign objects can be caught under the valves,thereby holding them open and causing rapid cutting of the seats and valves.

24. BN> CHARGING PUMP

When assembling new bearings, check the clearance between the impeller vane and the casing with a piece of shim stockbefore locking the bearings on the shaft. This clearance should not exceed .010. Periodic checking of this clearance isrecommended to maintain pump efficiency.

Bearings (Charging Pump)

Ball bearings are grease lubricated and packed with grease at the factory. When relubricating, it is recommended that regularball bearing grease be used. All leading oil companies have a regular ball bearing grease.

Heating of bearings invariably means too much grease instead of an insufficiency and careful inspection to determine thetrouble should be made before more grease is added. An ordinary tablespoonful is sufficient and will serve to lubricate thebearings for a period of three months of normal service.

Great care should be exercised to keep housing immaculately clean and only clean grease should be used for lubricatingbearings. Under no circumstance should grease which has been used before be used. Fore

dsolids or liquids invading housing

can com letely ruin the bearings in a short time.b

It is important to use clean tools an cloths when cleaning housing andgreasing earings.

If ease is applied to bearings with a pressure gun, the pipe plug in the bottom center of bearing housing must be removedfbe orehand. As new grease is added, old grease is forced out into this housing, Do not allow o d grease to completely fill

PJ-400 Page 10

this housing as heating of bearings will result. To remove accumulation of grease, clean housing each time pump is dismantledfor inspection, Under normal conditions of lubrication and service, this would be approximately once every year.

When packin the ump the following procedure must be rigidly followed: Three rings of packing are to be inserted intothe stuffing box, f ollowed by the seal cage, then two rings of packing. The rings are to be spaced so that the splices arestaggered. After the rings are placed, glands are put into position and inserted into the stuffing box tight enough to permitjust a few drops of water to drip out per minute. This slight amount of water helps to lubricate the pump shaft at thepacking joints.

Customer is to equip the stuffing box with a grease cup having a ball check.

AS an alternate, the stuffing box may be connected to a source of clear cold water having apump discharge.

pressure greater than that of the

Belt Drive (Charging Pump)

When installin pump for V-belt drive, belts must be in perfect alignment for any slight misalignment will cause excessive beltwear. This will shorten materially the life and the use of the belts. V-belts should only be tight enough to prevent slippage.

25. RECOMMENDED RUNNING CLEARANCES (Inches) FEELER

Min. Max.

Crosshead to Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jackshaft Bearing, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crosshead Pin Bearing, ..,.... . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Liner to Eccentric (On Horizontal Centerline). .

Oil Pump Pinion to Main Gear-Backlash . . . . . . . . . . . . . . .

Jackshaft to Main Gear - Backlash . . . . . . . . . . . . . . . . . . . .

.010

.002

.002

.0005

.008

.010

.010

.018

.004

.003

.0015

.010

.020

.020

26. MANUFACTURING FITS (Inches) ACTUAL

Min.

Jackshaft Bearing OD in Housing . . . . . . . . . . . . . . . . . . . . . . .0003Tight

Jackshaft Bearing on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . .0003Tight

Crosshead Pin Bushing OD in Connecting Rod. , . . . . . . . . . . . .003Tight

Main Bearing OD in Eccentric.. . . . . . . . . . . . . . . . . . . . . . . .0026Tight

Main Bearing on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004Tight

Max.

.0021Loose

.0021Tight

.005Tight

.0008Loose

.0015Loose

27. RECOMMENDED TORQUES

Cylinder Frame Stud Nut(185 Lb, Manon4-1/2 Ft. Wrench) ...,.... . . . . . . . . . . . . . . . . . . . . . . 800 Ft. Lbs.

Connecting Rod Bolt(185Lb. Marion 2-1/2 Ft. Wrench), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 Ft. Lbs.

Piston Rod Nut

Stuffing Box to

(185 Lb. Manon6Ft. Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . lllOFt. Lbs.

Frame Stud Nut(185Lb. Marion 3-l/4 Ft. Wrench) . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Ft. Lbs.

PJ-400 Page 11

PJ-400

Page

12

STRAINERIN SUCTIONMANIFOLD

DISCHARGE =.* I I

NOTES:SUCTION CAN BE CONNECTED TOEITHER END OF MANIFOLD.

DISCHARGE CAN BE CONNECTED TOEITHER END OF MANIFOLD.

DISCHARGEMANIFOLD

RELIEFVALVE

7

PRESSURE RELEASE VALVE-B

RELIEF VALVE

TOSUCTIONGAUGE ,

MUD TANK ~w

1;1 )1PRESSURE l-n I

-TO MUD TANK

CENTRIFUGAL

(AVAILABLE FoROR LEFT HAND

RIGHTMOUNTING)

FIGURE 6. RECOMMENDED TYPICAL SUCTIONPIPING ARranGEMENT

B70330

AND DISCHARGE

PJ-400 Pag13