a e NATIONAL OILWELL A1700-PT TRIPLEX PISTON PUMP INSTALLATION, CARE AND OPERATING MANUAL NATIONAL-OILWELL, P.O. BOX 4638 HOUSTON, TEXAS 77210-4638 ‘As used he ences to OILWELL shall be deemed to mean NATIONAL-OILWELL SM: 5-90 Printed in U.S.A.NATIONAL OILWELL FOREWORD ‘This manual is published as a guide for the normal operations of your NATIONAL-OILWELL equipment. Because of the many factors which contribute to the proper function ot malfunction of this machinery, and not having complete knowledge of each factor or combination of factors, we cannot detail all facets of this subject. We must therefore confine the scope of this presentation, and when situations encountered are not fully encompassed by complete understandable instruc. tions, these situations must be referred to the manufacturer. When other than routine servicing is necessary, it can be most efficiently performed if the unit is removed to an area of adequate space where an overhead crane, hydraulic lift, bearing pullers, impact tools, etc., are accessible, ‘The dimensions and tolerances specified in this publication are those desirable for the most efficient operations of the equipment. When components become worn or when new parts are introduced into a worn unit, it may not be possible or economically feasible to re-establish such strict alignment and correct all dimensional deviations. Improvements in design, engineering, materials production methods, etc., may necessitate changes in these products and result in inconsistencies between the contents of this publication and the physical equipment. We reserve the right to make these changes without incurring any liability or obligation beyond that stipulated in the purchase contract. THE PICTURES, PHOTOGRAPHS, CHARTS, DIAGRAMS, DRAWINGS, VERBAL CON- TENTS AND SPECIFICATIONS CONTAINED HEREIN ARE NOT TO BE CONTRUED AS GIVING RISE TO ANY WARRANTY ON THE PART OF NATIONAL-OILWELL. NATIONAL- OILWELL MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, BEYOND THAT STIPULATED IN THE PURCHASE CONTRACT. CAUTION Exercise safety in all performances, do not ignore any cautions, used only approved methods, materials and tools. Do not permit any function of questionable safety because accidents are caused by unsafe acts and unsafe conditions, SAFETY I$ YOUR BUSINESS AND YOU ARE INVOLVED. AWarning Before performing any service function be certain that the unit is separated from its power source or that the power source is locked-out to prevent any form of energy from entering the equipment. This would include electrical or mechanical energy into or from the prime mover/s, Pneumatic energy from the compressor/air system, etc. The traveling equipment should be sus- pended from the hang line and the mechanical brake released to ensure there is no load on the drum that may cause unintended rotation. The sub-assemblies of this unit represent massive weights and must also be suspended before being released from their operating positions. NOTICE FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICA- ‘TION CAN RESULT IN PROPERTY DAMAGE, SERIOUS BODILY INJURY OR DEATH. EESS | NATIONAL OILWELL Table Of Contents : DESCRIPTION PAGE Introduction 2 Standard Composite Details ..... pe000 3 General ... Fluid End - Fluid Chambers ...........- Pistons And Liners .... Valve Service. Power End...........-5 eee 1618) Diaphragm Assembly.............. ee eee 121) Pinion Shaft Assembly + 22-25 Crankshaft Assembly. . .. Jackshaft Assembly... Crossheads. ..... Connecting Rods... Lubrication, Internal Lubrication Assembly . . 46 & 47 isxternal Lubrication Systear see eee rece te 48-50 Liner Flushing System Strainer Maintenance Appendix Viscosity Equivalents Chart........ | Sopsecnoua oo) Sales and Service. . «+» Back Covera] Introduction * ‘This manual is published as a guide for the disassembly and re-assembly of your unit. The recommendations made here for the performance of normal servicing are based on many years of experience in the manufacturing, maintenance and servicing of this equipment, however unusual or extreme circumstances may arise and these must be referred to the manufacturer's technical services department, Improvements in design, engineering, materials, production methods, etc., may necessitate changes in this product and result in inconsistencies between the contents of this publication and physical equipment. We reserue the ight to make these changes without incurring any obligation for equipment Previously or subsequently delivered. ‘The manufacturer will upon request and contract provide trained, experi. enced personnel to assist you in the maintenance and servicing of this machinery. ‘This materials used in construction of National-Oilwell mud pumps are suitable for use in sour gas (Hydrogen Sulfide) environments ONLY if the drilling fluid environment is controlled as specified in the National Associa- tion of Corrosion Engineers (NACE) Standard MR-01-75, 1984 Revision. Paragraph 11.2 and particularly sub-paragraph 11.2.2 which provides: “11.2.2 - The drilling environment is controlled by main of drilling fluid hydrostatic head and fluid density to minimize formation fluid in-flow and by the use of one or more of the following: 1) maintenance of pH 10 or higher to neutralize H9S in the drilled formation, 2) Use of chemical sulfide scavengers, and 3) Use of a drilling fluid in which oil is the continous phase.” Failure to control the drilling fluid environment as specified above can result in sulfide stress cracking of certain components. Such cracking may result in subsequent failures causing serious personal injury and/or property damage. NATIONAL OILWELL,| NATIONAL OILWELL Standard Composite Details Variations in requirements may demand relocation or the omission of cer- tain components on a specific pump, therefore please inspect your unit and become familiar with its equipment and details. one cites (1) Magnetic Oil Filter (9) Cradle Drain * (2) Cartridge Type Oil Filter (10) Flushing Fluid Sump Drain (3) Crankease Oil Level Dipstick (11) Heat Exchanger * (4) Piston Rod Back-up Tool (12) Motor Driven Flushing Pump (5) Crankease Oil Drain * (13) Fluid Chamber No. 1 (Left Hand Side) (6) Electrically Driven Lube Oil Pump (14) Fluid Chamber No. 2 (Center) (7) Oil Pressure Gauge (15) Fluid Chamber No. 3 (Right Hand Side) (8) Sludge Drain Not illustrated. (Figure 1)a] General ‘The basic pump is comprised of a power end and a fluid end mounted on short steel skids. The power end contains the shaft assemblies, connecting rods, diaphragms, etc. The fluid end contains the fluid chambers, suction manifold, discharge manifold, valves, seats, pistons, liners, ete. ‘The lubrication system with its provisions for filtration and cooling, the liner flushing system filtration and cooling, the liner flushing system with its circulation unit, the features of a piston rod back-up tool, the mechanical turning device, etc. are all added to the basic unit to compose the standard unit as outlined in this publication, The laterality of the unit is as reflected here, determined by standing at the power end, and looking toward the fluid end - reference is made to the left hand side, and the right hand side. ‘The fluid chambers are also designated from this same position - the No. 1 fluid chamber is on the left hand side, the No. 2 chamber is in the center and the No. 3 chamber is on the right hand side, NATIONAL OILWELLLL | NATIONAL OILWELL Fluid Chambers ‘The fluid chambers are three separate blocks or cylinders which are bolted to the power frame and assembled with the suction and discharge manifolds, ‘The valve seat bores and the liner adapter bore are machine formed into each cylinder. (6) Fluid Chamber Suction Manifold Discharge Manifold Valve Cover Piston Assembly Piston Rod (Figure 2) (7) (8) (9) (10) qa) (12) Piston Rod Extension Liner Liner Wear Plate Liner Adapter Liner Nut Liner Flushing Shield ————NATIONAL OILWELL apes Fluid Chambers A. GENERAL ‘The individual cylinder design makes possible the replacement of a sin- gle segment rather than the replacement of a complete, one piece, three cylinder, monoblock fluid end. The suction and discharge manifolds are bolt-on type and are also individually replaceable. B, MAINTENANCE 1, Maintain proper tightness of all fluid end bolting.* 2. Care should be taken to maintain clean and undamaged “O” ring and mating metal-to-metal surfaces. 3. Keep valve covers tight. Refer to VALVE SERVICE in this publi- cation for instructions. 4. ‘Tell Tale” holes have been provided in the valve chambers. Any leakage past the valve cover gasket will be discharged through these openings. If leakage is detected, immediately tighten the valve cover 6 or replace the gasket, otherwise fluid cutting or a wash out will occur. 5. Refer to PISTONS AND LINERS and VALVE SERVICE in this pub- lication for additional maintenance. ©. REMOVAL 1. Remove the suction manifold and the discharge manifold. Note: The suetion and discharge lines should be drained before removing the manifolds. 2. Remove the valve covers and the valve assemblies, Refer to VALVE SERVICE in this publication for instructions. 3. Remove the piston and liner assembly. Refer to PISTONS AND LINERS in this publication for instructions. 4, Support the fluid end segments and prepare to remove the hex nuts at the bottom of the fluid chamber, then the hex nuts at the top of the segment. Slide the segment forward until it is clear and remove it to the proper work area. 5. With the fluid end segment properly supported and secured on a work table, unscrew and remove the liner adapter. It may be necessary to use chain tongs on the reduced portion of the adapter for this removal. ey *Torquing values will be found in the APPENDIX of this publication,SS Fluid Chambers 6.Clean and inspect the liner wear plate for damage and corrosion pitting. If it must be replaced weld a puller bolt to the liner wear plate and use a weighted “knocker” to remove the liner wear plate. Remove the wear plate gasket. INSTALLATION 1. Carefully clean and inspect all parts for damage and wear, replace if necessary. 2, Place the gasket on the liner wear plate and press the plate into posi- tion inside the fluid chamber. 3. Coat the fine threads on the liner adapter with a good quality anti- seize compound and screw the adapter into the fluid chamber. Use a heavy chain tongs on the reduced portion of the adapter and apply a torque to 2000 lb-ft. 4, Position the fluid end segment on the power frame and retain snugly, but right with the upper and lower hex nuts. 5. Install the discharge manifold. Be certain that the “O” rings are in place and tighten the hex nuts.* 6. Install the suction manifold. Be certain that the “O” rings are in place and tighten the hex nuts.* 7. The installation of the discharge and suction manifolds should have aligned the fluid end segments. Check to be certain that this has been accomplished, then apply full torquing to the upper and lower fluid end retaining nuts.* 8. Install the piston and liner assemblies. Refer to PISTONS AND LINERS in this publication for instructions. 9. Install the valve assemblies and valve covers. Refer to VALVE SER- VICE in this publication for instructions. 10. Before returning the pump to service, refer to and be guided by the instructions listed under PLACING IN OPERATION in your opera- tors manual. ¥Torquing values will be found in the APPEND. of this publication, NATIONAL OILWELL.i NATIONAL OL WELL que Piston And Liners The pistons and liners in a reciprocating pump are subjected to severe condi- tions which promote rapid wear, proper maintenance and replacement parts of highest quality are necessary to extend the service life of these com- ponents. The piston assemblies are API type SA-4 and the liners are SUPER DI-HARD. 13) (1) Piston Rod Nut (2) Retaining Plate (8) Piston Rubber (4) Piston Body (5) Piston Rod Stud (6) Set Screw (7) O-Ring (8) Piston Rod (9) Wear Plate Gasket an 2 3 1G 1 cay 4) @ | 13 (Figure 3) ae (10) Liner Wear Plate (11) Liner Gasket (12) Liner Adapter (13) Fluid Cylinder Liner (14) Liner Retaining Nut (15) Liner Flushing Shield (16) Piston Rod Extension (17) Extension Rod Clamp (18) Crosshead Extension (19) Spacer Ring * (20) Spacer Ring * * Not used with 614” and larger diameter Piston and Liners.FY ATIONAL OIL WELL Piston And Liners r A. GENERAL ‘The pump is normally shipped with the pistons unassembled. Refer to INSTALLATION instructions which follow for detailed assembly. ‘The Type SA (Single Acting) piston includes a back seal ring of special compound which in addition to providing a positive seal, carries lubri- cation from the flushing system to reduce heat and friction between the piston and liner. ‘The API SA-4 piston rod has been provided with an extension to facili- tate removal of the piston/piston rod assembly. Both of these parts are phosphate coated for protection against corrosion, B. MAINTENANCE 1, Keep liner, piston, piston rod, and piston rod extension tightly in position * 2. Keep the liner flushing system flowing at the proper rate filled with the proper lubricant and free of contamination. 3. Replace worn or deteriorated piston assemblies immediately. 4, Maintain liners in good condition or replace to prevent piston failures. 5. Replace liner gasket if leak is detected and each time a liner is in- stalled. 6.Replace the piston rod nut if damaged or if seal is deteriorated, 7. Use only a box end wrench on the piston rod nut (a pipe wrench will squeeze the nut causing distortion and incorrect torquing value). ©. REMOVAL 1, Disconnect the pump from its power source. 2.Use a socket end wrench on the hex head of the jackshaft exten- sion to rotate the pump bringing the extension rod clamp and ex- tension rod into the most accessible position. 3. Remove the extension rod clamp. 4. Remove the liner flushing shield. It may be necessary to rotate the pump jack shaft to provide clearance between the crosshead ex- tension rod and the piston rod extension for removal of the shield. 5. Unserew the piston rod extension from the piston rod using two open end wrenches on the wrench flats. A *Torquing values will be found in the APPENDIX of this publication,NATIONAL OFLWELL pe Piston And Liners Cc, REMOVAL 6. Place the open end of the piston rod “tool” on the button end on the crosshead extension and rotate the jackshaft to engage the threads on the other end of the tool with the threads on the piston rod, Screw the tool onto the piston rod. 7. Rotate the pump jackshaft to withdraw the piston/piston rod assem- bly from the liner. 8. The three dog point set screws in the liner nut should be adjusted to place the dog of the screw well inside the groove of the liner, but not jammed or set in the bottom of the groove. Place a brass bar on one of the lugs on the liner nut and strike the brass bar with a sledge hammer to unscrew the nut which in turn will with the setscrews riding inside the liner groove, withdraw the liner from the fluid chamber. 9,Remove the setscrews from the liner nut, then remove the liner nut and the liner with its gasket from the pump. 10. Protect the threaded end of the piston rod assembly and place the 10 assembly in the “back-up” tool located at the rear of the pump skid. Using a splined wrench unscrew the piston rod nut and remove the component parts of the piston assembly. Piston Rod r Piston Rod Tool oy iy ) Crosshead Extension (Figure 4) IPiston And Liners D. INSTALLATION 1. Carefully clean and inspect all parts for damage and wear and replace if necessary, 2. Clean the surface of the liner wear plate. If corrosion or wear damage is present, replace the wear plate and wear plate gasket. 3. Remove any paint and polish the O.D. of the liner, place the liner gasket on the liner and place the liner inside the liner adapter. 4. Using a good quality multi-purpose, grease lubricate the exposed portion of the liner, the threads on the liner adapter and the inner surface (including internal threads) of the liner nut, 5, Remove the setscrews from the liner nut and screw the nut onto the liner adapter. When the nut is tight, place a brass bar against one of the lugs and striking the brass bar with a sledge hammer, continue to tighten the nut until firm metal-to-metal contact is achieved be- ‘tween the liner wear plate, the liner, and the liner nut. 6. Check the inner bore of the liner to be certain that the liner gasket has not become misplaced during installation. 7 Replace the setscrews in the liner nut, but do not tighten these against the liner (the setscrews are used only at the time of liner removal). 8, Make the piston/piston rod assembly by placing the piston rod in a vise with the piston end of the rod in the top vertical position and in- stall the following on the rod in sequence: (a) “0” Ring (@_ Retaining Plate (b) Piston Body (e)_ Piston Rod Nut (c) Piston Rubber (f)_ Snap Ring Tighten the piston rod nut by protecting the threaded end of the rod against damage and placing it in the “back-up” tool at the rear of the pump skid and torquing the nut with a box end wrench. # 9, Lubricate the piston with a light coating of grease or oil and screw the piston rod “tool” on the end of the piston rod. Place the open end of the piston rod “tool” over the button end of the crosshead exten- sion, align the piston with the bore of the liner, then rotate the pump jackshaft to force the piston into the liner. Exercise care during in- stallation to prevent damage or “roll back” of the piston rubber lips. 10. Remove the piston rod “tool” and install the piston rod extension, Use two open end wrenches to tighten the piston rod extension on the piston rod.* 11, Install the liner flushing shield. 12, Install the extension rod clamp.* *Torquing values will be found in the AP NDIX of this publication, NATIONAL OILWELL 11 SSj NATIONAL OILWELL Valve Service ‘The valve chambers conform to API standards and the valve assemblies are interchangable suction and discharge. The chambers are drilled with “tell- tale holes which provides for the detection of leakage at the valve cover gasket. (1) Valve Cover (2) Valve Cover Gasket 4 (8) Upper Valve Stem Guide (4) Upper Guide Bushing (5) Valve Spring ve (6) Valve Nut (Figure 5) (1) Valve Dise (8) Valve Body (9) Valve Seat (10) Valve Seat BushingValve Service A. GENERAL ‘The valve seats are conical and fit into tapered bores in the fluid cham- bers. The valve stems are guided both top and bottom, and have a replaceable, flexible, elastomer insert type disc to seal against back-flow. . MAINTENANCE, 1. The valve seats must be retained firmly in place to prevent serious damage to the pump. 2, Periodic replacement of the valve disc, prior to fluid cutting will extend the life of the valve body and valve seat, 3. Systematic replacement of the upper and lower valve stem guides will Provide for the proper seating angle of the valve into the valve seat. 4. Replace damaged or fluid cut assemblies immediately. It is recom— mended that a complete assembly be installed rather than placing a new valve in a used valve seat. 5. Keep the suction and discharge manifold bolting tight.* . REMOVAL 1,Remove the valve cover and the valve spring, The upper valve stem guide is bolted to the cover and is removed with the valve cover. 2. Lift out the valve assembly by inserting a nail or hooked wire through the hole drilled horizontally in the upper valve stem, 8. Using a valve seat puller, remove the valve seat. NEVER USE A CUT- TING TORCH TO REMOVE A VALVE SEAT. . INSTALLATION 1. Carefully clean and inspect all parts for damage and wear. Re- place if necessary. Any damage or fluid cuts in the valve seat bores must be repaired before installing new valve seats. 2. Thoroughly clean the valve seats and the valve seat bores using non- toxic, non-explosive mineral spirits or commercial solvents. If it is necessary to polish these surfaces, use fine emery cloth and re-clean. Dry the seat and the seat bore with an air hose - DO NOT LUBRI- CATE, 3. Place the valve seat in the valve seat bore, and place the valve in the seat, Place a short length of large diameter, heavy wall pipe over the *Torquing values will be found in the APPENDIX of this publication, NATIONAL OILWELL 13 SSi NATIONAL OILWELL Valve Service (1) Valve Cover (2) Valve Cover Gasket (3) Upper Valve Stem Guide (4) Upper Guide Bushing (5) Valve Spring igure (6) Valve Nut ae (7) Valve Dise (8) Valve Body (9) Valve Seat (10) Valve Seat BushingValve Service D. INSTALLATION NATIONAL OILWELL upper valve stem and using a sledge hammer to strike the pipe, drive the valve seat into place. ‘The seat should be firmly in place when the pipe bounces free with each blow from the sledge hammer. 4. Install the valve spring. Use a new spring with each new valve body. 5. Thoroughly clean the gasket surface and threads on the valve cover, and in the valve chamber. Repair any damage found on the gasket surfaces. Lubricate a new gasket with a light coating of grease and place it in the counterbore of the fluid chamber. 6. Apply a liberal amount of a good quality anti-seize compound on the threads of the valve cover and the threads in the fluid end segment. Install the valve cover. Be certain that the valve spring is in place, and that the upper valve guide bushing is over the valve stem, 7. Tighten the screw type valve cover by placing a heavy bar in the holes provided and bumping the bar if necessary. Never pound directly on the valve cover. 15i NATIONAL OILWELL quae Power End ‘The power end of the pump is comprised of six sub-assemblies as listed below, and a lubrication system which for clarity has been divided into four section in this publication. (Figure 7) (1) Power Frame (2) Diaphragm Assembly (3) Crosshead Assembly {4) Connecting Rod Assembly (5) Crankshaft Assembly (6) Pinion Shaft Assembly (7) Jack Shaft Assembly (Not Illustrated)Power End A. GENERAL ‘The power end of the pump is designed with access covers and doors of maximum size consistent with material requirements for rigidity and strength of the power frame. Specific instructions for the removal and reinstallation of each sub- assembly are detailed in the continuing text. B, MAINTENANCE, ‘To prevent the necessity of removing the sub-assemblies because of im- proper care. It is recommended that the minimum maintenance program outlined in the OPERATORS MANUAL be initiated and expanded to meet specific requirements. . REMOVAL. 1.To remove the power end of the pump requires hoisting equipment with capacity for the safe handling of the weight. 2.Separate the pump from its power source and remove the drive arrangement, i.e., the drive guard, sheaves, sprockets, couplings, etc. 3. Remove the fluid chambers. Refer to FLUID CHAMBERS in this publication for specific instructions. 4. Drain the liner flushing system, Drain the lubricating oil including the sludge drain. 5. Disconnect base mounted drain lines, and lubrication lines. Disconnect all electric lines to pump safety switches. 6. If shear blocks have not been welded on the base, apply these at this time in order that the power end can be returned to the base and aligned to its original position. For welding instructions refer to the APPENDIX of this publication, 7. Remove the hold-down capscrews at the base of the pump power frame and lift the power end from the steel base. Do not attach hoist- ing lines or pick-up lines to the pinion shaft or across any machine surface of the power frame, D. INSTALLATION 1. Be certain that the steel base is clean and level, then place the power end on the base. 2, Install the hold-down capscrews, but do not tighten. *Torquing values will be found in the APPENDIX of this publication. NATIONAL OILWELL 17 LLj NATIONAL OFLWELL guppsssssas Power End D. INSTALLATION 3.Connect the drain lines and lubrication lines to the power frame. Connect safety switches, 4. Install the fluid chambers. For instructions refer to FLUID CHAM- BERS in this publication. 5. Install the drive arrangement and align the prime mover(s) with the pump. Instructions for alignment are contained in the OPERATORS MANUAL which accompanied shipment of the pump. 6. Tighten the hold-down bolts.* Recheck the alignment of the unit and adjust if necessary. Secure the alignment, 8. Replace guards, safety railings, etc. 18 9. Fill the crankcase and liner flushing reservoir as outlined in the OPERATORS MANUAL and be guided by other instructions detailed under PREPARING FOR OPERATION and PLACING IN OPERATION in the OPERATORS MANUAL. Sc *Torquing values will be found in the APPENDIX of this publication.| NATIONAL OILWELL Diaphragm Assembly ‘The diaphragm is a dual purpose assembly designed to: 1) keep the lubri- cating oil in the crankcase, and 2) keep foreign material that collects on the crosshead extension rod from entering the crankcase and contaminating the lubricant. 19 (1) Diaphragm Cover (2) Lantern Rings (2) (metal) (8) Wiper Rings (3) (Elastomer) (4) Dowel Pins (5) Diaphragm Housing (6) Vent Hole (7) Housing Gasket (8) Crosshead Extension Rod (9) Drain Hole (Figure 8) (10) Diaphragm SupportNATIONAL OL WELL queen Diaphragm Assembly A. GENERAL This is a simple assembly, but it is most important in preserving the quality and condition of the lubricant. B, MAINTENANCE 1, Keep the diaphragm supports firmly in place. 2, Keep the housing capscrews tight.* 3. Be certain that the drain hole in the housing is at the bottom of the the assembly. 4. The wiper rings are non-adjustable and to prevent these from working inside the diaphragm’, metal-to-metal contact between the diaphragm cover (or gland) and the diaphragm housing is necessary. 5. Keep the vent holes in the diaphragm cover (or gland) and housing free of obstructions. 6.Should leakage occur, replace the wiper rings immediately and if 20 necessary, replace the crosshead extension. 7. Should some failure occur at the fluid end of the pump which causes the pumped fluid to “blast” the diaphragm area or flood the cradle section of the pump, immediately remove the pump from service and change the oil in the crankcase, including the sludge reservoir. C. REMOVAL 1, Remove the extension rod clamp. Refer to PISTONS AND LINERS in this publication for instructions, 2, Continue to rotate the shaft assemblies to separate the end of the crosshead extension from the piston rod extension. 3. Remove the capscrews and lockwashers from the diaphragm housing assembly and slip the assembly over the end of the crosshead exten- sion, 4, With the diaphragm housing assembly removed from the pump, sepa- rate the assembly by removing the diaphragm cover, the three wiper rrings and the two lantern rings. D. INSTALLATION 1. Carefully clean and inspect all parts for damage and wear and replace if necessary TT *Torquing values will be found in the APPENDIX of this publication,Diaphragm Assembly D. INSTALLATION 2. Cover the wiper rings and the lantern rings with a thin coating of oil and in sequence install a wiper ring, lantern ring and wiper ring in the diaphragm housing. The sealing inner lip of the first wiper ring installed in the diaphragm housing must be directed inward (toward the power frame) to keep the lubricant from being carried out of the crankcase by the crosshead extension. ‘The sealing lip of the second wiper ring installed in the diaphragm housing must be directed out- ward (toward the fluid end) to wipe foreign material from the exten- sion rod, Use a block of wood to drive the wiper rings into position, exercise care to prevent damage to the rings. 3. Use a block of wood to drive the third wiper ring into the diaphragm cover. The sealing inner lip of the wiper ring must be directed out- ward (toward the fluid end) to wipe foreign material from the exten- sion rod. 4, Lightly oil the crosshead extension rod and place the diaphragm housing with its gasket, the installed wiper rings and lantern ring on the extension rod. 5. Place the second lantern ring on the extension rod. 6. Place the diaphragm cover with its installed wiper ring on the exten- sion rod. 7. Guide dowels have been provided to position, the diaphragm cover on the diaphragm housing. Match the dowels with the drilled holes and move the assembly against the diaphragm support and install the cap- screws.* 8. The guide dowels between the diaphragm cover and housing should have properly located the vent holes in the diaphragm cover. The in- dexing of the capscrews should have located one of the drain holes in the diaphragm housing at the bottom of the assembly. Check the locations of the vent holes and the drain holes to be certain the assem- bly has been properly installed. 9. Install the extension rod clamp. Refer to PISTONS AND LINERS in this publication for instructions. NATIONAL OILWELL 21 el *Torquing values will be found in the APPENDIX of this publication.j NATIONAL OILWELL : Pinion Shaft Assembly ‘The pinion shaft with integral pinion is extended on both sides of the power frame to permit driving forces to be applied to either the right hand side, left hand side or both sides. DIGIOIOIONG 2 SP | 22 (Figure 9) Shaft W/Integral Pinion (2) Pinion Shaft Bearings (8) Pinion Shaft Bearing Housing (4) Shim Set (5) Bearing Retainer (6) Oil Seal (1) Shaft Sleeve (8) Pinion Shaft Key (9) Extension CoverSL NATIONAL OILWELL Pinion Shaft Assembly F A. GENERAL The pinion shaft is mounted in two spherical roller bearings and may be removed from either side of the pump. When removal is necessary, select the side that has the best accessibility. B, MAINTENANCE 1, Maintain proper lubrication. 2, Keep the oil seals functionable. 3. Keep the pinion bearing retainer capscrews tight.* 4. Keep the pinion bearing housing capscrews tight.* Cc. REMOVAL 1. Remove the drive arrangement from the pinion shaft, ice., sprockets, coupling, keys, etc., and provide a work area with a mini- mum of six feet (from the side of the pump) to remove the pinion shaft. 23 2, Remove the shaft extension cover. 8. Remove the capscrews from the pinion bearing retainers and slip the retainers with their shims and oil seals over the end of the shaft. Exercise care in this removal to prevent damage to the oil seals. 4, Remove the crankcase cover, 5, Support the pinion shaft on both ends and remove the capscrews from the bearing housing opposite the side from which the shaft will be removed. Remove this bearing housing and its gasket. Jack screw holes are provided for this removal. 6. Remove the capscrews from the housing at the other end of the shaft. ‘The assembly should now be free to be pulled from the pump, if not, use jack screws to remove the second bearing housing from the power frame, 7.In the removal of the shaft assembly exercise care to prevent damage to the gears and bearings. It may be necessary to install a heavy threaded bar in the threaded opening in the end of the pinion shaft to guide and support the assembly during the removal. 8. With the shaft assembly adequately supported in wooden “V" blocks, use puller bolts to remove the shaft sleeves and a bearing puller assembly to remove the bearings. — ‘orquing values will be found in the APPENDIX of this publication.NATIONAL OIL WELL qq Pinion Shaft Assembly D. INSTALLATION 1. Carefully clean and inspect all parts for damage and wear and replace if necessary. 2, Place the pinion shaft bearings and shaft sleeves in a vat containing 115% soluble oil in water and heat to approximately 200F. 3. In some pump models there are bearing spacers adjacent to the bearing shoulders on the pinion shaft. If this pump is so equipped and these have been removed from the shaft be certain that they are replaced in the proper position before proceeding with these instructions. 4, Install the heated bearings and shaft sleeves in operating position on the shaft. The sleeves are to be installed with the taper inward and the puller bolt holes outward. Hold the bearings and sleeves in place until cooled. 5. Support The pinion shaft assembly and place it in its operating posi- tion inside the power frame. Exercise care in this installation to pre- vent damage to the bearings and gears. 6. Oil the machined surfaces of the pinion bearing housings, place the 24 gaskets on the housings and install these in the power frame. During this installation it is necessary that the shaft assembly be supported and centered in the openings to permit the housings to be fitted over the bearings and inside the frame openings. NOTE: The bearing housings are marked to indicate the “TOP” and must be installed in this position. When the housings are in proper position, tighten the capscrews.* 7.Center the pinion shaft assembly in the power frame, Check to be certain that the ends of the pinion shaft are equal distance from the sides of the frame and that the pinion is horizontally centered on the main gear. Place the pinion shaft bearing retainer (less shims and less oil seal) on the right hand** extension of the pinion shaft, and install the capscrews, but do not tighten. Adjust the capscrews to cause full surface contact between the inside of the bearing retainer and the bearing (excessive tightening of the capscrews will move the shaft assembly from its centering). Use a feeler gauge to measure the opening (or gap) between the retainer and the bearing housing. Remove the retainer and reinstall using clean flat shims with a total thickness equal to that measured with the feeler gauge. ‘Install and tighten the cap- serews.* NOTE: The bearing retainers are marked to indicate the “TOP” and must be installed in this position. 8. Place the pinion shaft bearing retainer (less shims and less oil seal) on the left hand** extension of the pinion shaft and install the cap- screws, but do not tighten. Adjust the capscrews to cause full surface contact between the inside of the bearing retainer and the bearing. Use aT *Torquing values will be found in the APPENDIX of this publication. **Right Hand and Left Hand Sides of the pump are determined by standing at the power end and looking toward the fluid end.es NATIONAL OILWELL Pinion Shaft Assembly t D. INSTALLATION a feeler gauge and measure the opening (or gap) between the bearing housing and the bearing retainer. Remove the retainer and reinstall using clean, flat shims with a total thickness equal to that measured with the feeler gauge PLUS AN ADDITIONAL .050" (1.27 mm) to 060” (1.52 mm) OF SHIMS. This will allow between .050” (1.27 mm) to .060” (1.52 mm) lateral clearance (or end play) of the pinion shaft during pump operation. Tighten the capscrews*, and check the lateral clearance, if found to be less than .050” (1.27 mm) or more than 060” (1.52 mm), readjust the assembly as outlined in paragraphs ‘Tand 8. 9. Install the oil seals in their proper sealing position. 10. Install the crankcase cover. 11. Install the shaft extension cover. 12. Install the drive arrangement. 25 *Torquing values will be found in the APPENDIX of th publication,j NATIONAL OL WELL queen Crankshaft Assembly During operations the crankshaft in the pump is generally heavily loaded and under this condition requires the protection of continous lubrication and the immediate replacement of worn or damaged main bearings, eccentric bear- ings, gears, bearing retainers, etc. When servicing is necessary it can be most efficiently performed if the pump is removed to an area where an overhead crane, hydraulic press, bearing pullers and other tools are accessible. (1) Crankshatt z igure 10) (2) Main Gear (3) Connecting Rods (4) Main Bearings (5) Main Bearing Housings (6) Main Bearing Housing Gaskets (7) Shim Sets (8) Main Bearing Retainers (9) Eccentric Bearing (10) Eccentric Bearing Retaining RingsCrankshaft Assembly A. GENERAL ‘The crankshaft is mounted in two heavy duty, spherical roller bearings, and is fitted with a replaceable main gear. The main bearings require no adjustment, however shim sets are included in the assembly to provide for lateral clearance (or end-play) of the crankshaft. |. MAINTENANCE 1. Maintain proper lubrication, 2. Keep the body fitted bolts, adjacent to the main bearing housings, tight.* 3. Keep the capscrews in the main bearing housings and main bearing retainers tight.* 4. Keep the connecting rod bolts tight.* 5. Keep the eccentric bearing retainers and retaining rings tight.* 6. Keep the main gear capscrews tight.* 7.Check the main gear periodically for condition and uniform wear. REMOVAL 1. The crankshaft is removed from the pump as an assembly which in- cludes the main gear, The main bearings and the eccentric bearings. .. Support and remove the crankcase cover. . Drain the lubricant from the crankease. ee NS Remove the oil troughs from the lower side of the connecting rods. Remove the connecting rod caps and move the connecting rod/cross- head assemblies forward in the pump. NOTE: Support the connect- ing rods and the caps during this removal to prevent damage to the crosshead guides, connecting rods, bearings, etc. NOTE: The connect- ing tod caps are matched with their respective connecting tods and are punch marked with identifying numbers, be certain that these caps are not mixed and when re-assembled are placed in the same relative position from which they were removed 6. Remove the main bearing retainers with their shims sets. Remove the lubricating oil lines from the main bearing housings. 8, Remove the capscrews from the main bearing housings. On both sides of the pump, install (at the 4 and 10 o’clock positions) two 14” long support rods which have been threaded on both ends and have a *Torquing values will be found in the APPENDIX of this publication, NATIONAL OILWELL 27NATIONAL OIL WELL qT Crankshaft Assembly Cc, REMOVAL nut on the outer end. ‘These are installed in the holes vacated by the housing capscrews and are to support the bearing housings and are used as guides during re-installation. 9. Remove the body fitted bolts and the two frame segments retaining the main bearing housings. 10. Support the crankshaft assembly and pull the main bearing housings from the sides of the pump. Jackscrew holes are provided for this pulling and when loose the bearing housing will rest on the support rods which were installed as outlined in the foregoing. 11. Lift the crankshaft assembly with the main gear, main bearings and ec- centric bearings from the pump. 12, With the crankshaft assembly properly supported in an adequate work area, support the main gear, remove the main gearing retaining cap- screws, then remove the main gear. Two jackscrews holes are pro- vided and with the jackscrews evenly torqued the gear can be pulled from the shaft. NOTE: It is not necessary to remove the main gear unless it or the crankshaft is being replaced. 28 13. Use a puller assembly with a heavy plate and hydraulic jack to remove he main bearings from each end of the crankshaft, Support these bearings during removal and exercise care to prevent damage to the shaft or the bearings. If the puller plate cannot be placed behind the bearing assembly it may be necessary to remove the individual rollers and the outer race, then pull the inner race. Reliefs in the bearing inner race permit the removal of the rollers. If this action is necessary, consult the bearing manufacturer for specific instructions. 14, Remove the main bearing spacers (if the pump is so equipped). 15. Remove the eccentric bearing retainers (if the pump is so equipped) and remove the eccentric bearing retainer rings. 16. From the two outside eccentric bearings, remove the outer race with rollers, and roller retaining ring. 11. It is necessary to remove the inner race from the eccentric bearing most remote to the main gear before the center eccentric bearing is disassembled. To remove this inner race assemble a bearing puller and hydraulic jack to pull it evenly from the shaft. 18, Use the same puller and procedure to remove the inner race from the opposite end of the shaft. nyCrankshaft Assembly r ©. REMOVAL 19. Remove the outer race with rollers and roller retaining ring from the center eccentric bearing, then use the bearing puller with extended puller bolts to remove the inner race. D, INSTALLATION 1. Carefully clean and inspect all parts for damage and wear, replace if necessary, 2. Place the main gear in a horizontal, elevated position support the rim of the gear (the supports must be capable of withstanding the weight of the gear and the crankshaft), and place the crankshaft inside the main gear, NOTE: Determine the direction in which the pinion and main gear will rotate and assembly the main gear on the crankshaft to provide the most compatable mating surfaces in the meshing of the gear and pinion, 8. Carefully align the capscrew holes in the gear with the capscrew holes in the crankshaft. Insert two capscrews, of sufficient length with washer through the capscrew holes in the crankshaft and engage the threaded jackscrews holes in the main gear. Evenly tighten these cap- serews to pull the crankshaft into the main gear. NOTE: Carefully guide the crankshaft during this installation to prevent misalignment of the eapscrew holes, 4, Remove the “puller” capscrews and install the retaining capscrews and locknuts.* 5. Place the eccentric bearing inner races and the main bearings in a vat containing 15% soluble oil in water and heat to approximately 200°F. 6. Place the center eccentric bearing inner race in its position on the crankshaft. NOTE: The flange of the inner race must be in the direc- tion of the main gear. 7. Install the outer race with rollers and roller retainer (machined radius to the outside) on the center eccentric bearing race. Place the re- taining ring against the center eccentric bearing and evenly tighten the socket head capscrews.* 8. Follow the same procedure as outlined in the two foregoing para- graphs to install the eccentric bearing on the other side of the main gear. 9, Install the retaining ring (inward position) on the crankshaft and fol- low the procedures outlined in foregoing paragraphs 6 and 7 to in- stall the outer eccentric bearing. NOTE. In this installation be certain that the inner edge of the inner race is against the retaining ring on the shaft and that it is held in place until the inner race is cooled *Torquing values will be found in the APPENDIX of this publication, NATIONAL OILWELL 29 TC30 Crankshaft Assembly D. INSTALLATION 10. Install the main bearing spacers on both ends of the crankshaft (if the pump is so equipped). 11. Install the main bearings on opposite ends of the crankshaft. The reliefs (for removal of the bearing rollers) in the inner race should be positioned to facilitate the removal of the individual rollers. Hold the bearings firmly against the bearing spacers until the bearings are cooled. 12. With the main bearing housings and gaskets on the support rods posi- tioned on each side of the pump, lift the crankshaft assembly, and fit it into its approximate operating position inside the power frame. Exer- cise care during this installation to prevent damage to the bearings, connecting rods, crosshead guides, gear teeth, ete. 18. With the crankshaft assembly in its approximate operating position, oil the machined surfaces of the main bearing housings, push the main bearing housings over the main bearings and inside the openings in the power frame, Install the retaining capscrews and pull the main bearing housings evenly into place, 14. Install the two frame segments with the body fitted bolts and nuts.* 15. Install the connecting rod caps with their eccentric bearing retainers ‘on the connecting rods. Refer to CONNECTING RODS in this pub- lication for specific instructions. 16. Use the main bearing retainers (less the shims) as shaft “pushers” to center the main gear with the pinion. Check all three connecting rods, to be certain that there is clearance between the connecting rod and the inside faces of the crossheads. 17. With both main bearing retainers snugly against the main bearings, and the main gear centered with the pinion use a feeler gauge to measure the opening (or gap) between the retainer and the bearing housing on the left hand side of the pump,** Remove the retainer and re-install using clean, flat shims with a total thickness equal to that measured with feeler gauge. Install and tighten the capscrews.* 18. Use a feeler gauge to measure the opening (or gap) between the main bearing retainer and main bearing housing on the right hand side of the pump.** Remove this bearing retainer and re-install using clean, flat shims with a total thickness equal to that measured with the feeler gauge PLUS AN ADDITIONAL .050” to .060” OF SHIMS. This will allow between .050” to .060” of lateral clearance (or end play) of the crankshaft during pumping operations. Tighten the retainer cap- serews* and check the lateral clearance - if found to be less than .050” or more than 060” re-adjust the assembly as outlined in the foregoing Paragraphs 16, 17, and 18, *Torquing values will be found in the APPENDIX of this publication, NATIONAL OILWELL. NE **Right Hand and Left Hand Sides of the pump are determined by standing at the power end and looking toward the fluid end.NATIONAL OILWELL Crankshaft Assembly D, INSTALLATION 19, Refill the crankcase with the proper lubricant. Refer to LUBRICATION in this publication for specifications. 20. Energize the electric lubrication system to circulate the crankcase oil throughout the system and fill the oil reservoirs. If the pump is equip- ped with a mechanical lubrication system, remove the v-belt from the lubrication oil pump and use an electric orpneumatic drill motor to rotate the shaft of the oil pump to circulate the oil. 21. With the oil circulating as outlined above, activate the manual turning device to rotate the shaft assemblies and move the reciprocating parts to be certain that none are binding and can rotate or move unrestricted. 22. Install the crankcase cover and tighten the capscrews.* 31 eT *Torquing values will be found in the APPENDIX of this publication.j NATIONAL OILWELL Jackshaft Assembly ‘The Jackshaft Assembly provides an auxiliary drive for the lubricating oil pump, charging pump, etc., as well as a means of manually rotating the pump internal elemenis. The shaft is provided with a hexagon shaft ext— @ ension which can be driven with a socket wrench. (1) Jackshaft (2) Jackshatt Pinion (8) Bearing Spacer (Inner) (4) Jackshatt Bracket (5) Jackshaft Bearings (2) (6) Beating Retainer (7) Oil Seal (8) Oil Slinger (9) Oil Catcher (10) Bearing Spacer (Outer) (11) Drive Sheave (12) Hexagon Shaft Extension (13) Oil Reservoir (14) Oil Drain Hole (15) Washer, Nut, and Cotter PinJackshaft Assembly A. GENERAL ‘The jackshaft pinion meshes with the main gear to transmit positive rotation action outside the power frame to drive devices for the support or lubrication or pumping system. . MAINTENANCE 1. Keep the complete assembly firmly in place. 2. Keep the oil seal functionable. 3. Keep the drain hole open in the bottom of the oil catcher. 4, Do not permit the jackshaft pinion or the drive sheave to turn on the shaft. 5, Replace leaking gaskets immediately. 6. Do not use a pipe wrench on the hexagon end of the jackshaft. Use only a socket or end wrench. (This is the manual turning device). REMOVAL 1. Remove the crankcase cover for a visual inspection of the lubricating oil level. Drain the oil to lower the level to a point below the bottom capscrew holes in the jackshaft bracket. 2. Remove the v-belt guard and v-belts. 3.Remove the jackshaft brackets capscrews and pull the jackshaft assembly from the punip. 4, With the assembly in a suitable work area, remove the following in sequence: The drive sheave, the drive sheave key, the bearing retainer capscrews with lockwashers, oil catcher, oil slinger, and the bearing retainer with oil seal. 5. From the opposite end of the shaft, remove the following: The cotter pin, the slotted hex nut, the jackshaft washer, the jackshaft pinion, and the pinion key. 6. Use a hydraulic press or puller and remove the jackshaft bearings with their respective spacers from the jackshatt. . INSTALLATION 1. Carefully clean and inspect all parts for damage and wear, replace if necessary. NATIONAL OILWELL 33 SENATIONAL OIL WELL SY Jackshaft Assembly D. INSTALLATION 2, Place the jackshaft bearings and bearing spacers in a vat containing 15% soluble oil in water and heat to approximately 200° F, 3. Remove the heated inner bearing and spacer from the vat and place these in their operating position on the threaded end of the jackshaft, Hold these in place until cooled. 4. Place the jackshaft with the inner bearing and spacer in the jackshaft bracket and press the inner bearing into operating position. 5. Install the heated outer bearing on the shaft and inside the bearing bracket. It may be necessary to use a hydraulic press for this in— stallation. 6. With the outer bearing in place, install the heated outer bearing spacer. Hold in place until cooled. 34 ‘7. Install the following in sequence: The pinion, the pinion key, the washer, the slotted nut*, and the cotter pin, 8. On the opposite end of the shaft install the following in sequence: ‘The bearing reatainer with its gaskets, the oil seal, the oil slinger, the oil catcher, and the capscrews* with lockwashers. Be certain that the drain hole in the oil catcher is indexed 180° from the oil reservoir in the jackshaft bracket. 9. Install the drive sheave and the drive sheave key. Rotate the shaft to be certain it is free and not binding, 10. Place the gasket on the jackshaft bracket and position the assembly on the power frame. With the oil reservoir at the top of the bracket, Install the retaining capscrews* and lockwashers. 11. Install the v-belts and v-belt guard, —_—— *Torquing values will be found in the APPENDIX of this publication,| NATIONAL OILWELL Crossheads ‘The Crossheads stabilize the vertical movement, and to some degree the hori— zontal movement of the pump end of the piston rod during the reciprocating cycle. Alignment is critical to the proper function of the diaphragm, true axial movement of the piston, and concentricity of the piston in the liner. CROSSHEAD —CROSSHEAD —CROSSHEAD Asseely ASSEMBLY ASSEMBLY et a ed (1) Crosshead (2) Crosshead Guide (3) Crosshead Guide Retaining Clamp (4) Crosshead Inspection Door (5) Inspection Door Gasket (6) Crosshead Pin Retaining Plate (7) Crosshead Pin (8) Crosshead Pin BearingNATIONAL OLLWELL Crossheads A. GENERAL ‘The crossheads are heavily constructed, accurately machined ,and fitted into replaceable upper and lower crosshead guides. Shim adjustment of the guides will permit the maintenance of proper running clearance and compensate for wear. Correct crankshaft rotation is important to the service life of the crosshead assembly. The force transferred from the crankshaft to the crosshead should’ be above the horizontal center line of the crosshead which allows the crosshead to rest in the lower guide, and it is not being lifted to the upper guide during the power stroke, and then falling to the lower guide at the reversal point. B, MAINTENANCE 1.Maintain lubrication consistent with the instructions outlined under LUBRICATION in this publication. 2.As a MINIMUM, check the clearance in the assembly every six months, Use micrometers and feeler gauges to determine the follow- ing clearances: (a) Crosshead pin in crosshead. 36 (b) Crosshead in crosshead guides. 3.Normal running diametrical clearance should be maintained as follows: (a) Crosshead pin in crosshead: .000” to Minus ,003” (interference) (b) Crosshead in crosshead guides: 015” to .025" 4. Keep inspection doors and covers in place to prevent foreign material from collecting on the wear surfaces. C, REMOVAL 1, Disconnect the pump from its power source and provide a work area with a minimum of 3" clearance from the sides of the pump for re- moval of the crosshead pins, and an overhead hoist to lift the cross- heads from the pump. 2, Remove the crosshead inspection doors and gaskets from the sides of the pump. 3, Cut the locking wire from the crosshead pin retaining plate capscrews, remove the capscrews and retaining plates from the outside cross- heads. To service the center crosshead, locate the crosshead pina] Crossheads ©. REMOVAL retaining plate on the center crosshead, and remove the outer cross- head adjacent to that plate (refer to illustration and note that the crosshead pin retaining plate on the center crosshead, assembly “B” is on the right hand side, therefore the right hand crosshead, assembly “C” must be removed before servicing the center crosshead). 4,Remove the crosshead pins. Use two puller bolts in the crosshead pin with a heavy plate on the outer end of these bolts, bump the center of the plate with a sledge hammer or heavy bar to loosen the pin. In extreme cases it may be necessary to assembly a hydraulic puller or jack for this removal. CAUTION: Provide support for the pin and the puller assembly as it is freed from the crosshead. 5. Remove the extension rod clamp and the piston rod extension. On the 1400 and 1700 horsepower units, remove the liner retainer nut, and the liner in addition to the extension rod clamp and the piston rod extension. Refer to PISTONS AND LINERS in this publication for specific instructions. 6. Remove the diaphragm assembly, then remove the diaphragm sup- port. This creates an opening for the removal of the crosshead ex- tension and the crosshead. Refer to DIAPHRAGMS in this publica- tion for specific instructions. 7. Cut the locking wire from the capserews in the crosshead extension. Remove the capscrews and the crosshead extension 8. Rotate the shaft assemblies with a socket or end wrench on the hex head of the jackshaft extension to withdraw the crosshead end of the connecting rod from the crosshead. CAUTION: Place a block of wood under the end of the connecting rod to prevent it falling and damaging the crosshead guide. 9.Place a bar behind the crosshead (not through the crosshead pin opening), and slide the crosshead forward until it extends through the opening in the power frame. Install a lifting eye in the top center of the crosshead and attach a hoisting line to support the crosshead as it is removed from the pump. CAUTION: The crosshead in the lar- ger pumps weighs in excess of 700 pounds, and all must be guided and supported during removal. 10. Remove the lubrication lines at the rear of the upper and lower cross- head guides. 11. Support the upper guide; remove the lockwire, hex head capscrews, and retaining clamps which hold the guide in the pump power frame. Remove the upper guide. 12. Remove the lock wire, hex head capscrews, and retaining clamps from the lower guide. Remove the lower guide. NATIONAL OILWELL 37 ANATIONAL OIL WELL Crossheads Cc. REMOVAL 13. Use a puller bar with two metal plates and a “knocker” to remove the crosshead pin bearings from the connecting rods. The two metal plates should have an O.D. approximately 1/4” less than the O.D. of the crosshead pin bearing and these retained firmly centered on both sides of the bearing before applying the “kncoker”. If the bearing has been seized by the connecting rod, it may be necessary to use a hollow spindle hydraulic jack instead of the “knocker” to pull the bearing. If the jack is used, place a cylinder or piece of heavy pipe, with an LD. slightly larger than the O.D. of the bearing and a length equal to the width of the bearing, against the face of the connecting rod, and pull against this cylinder or pipe. Do not attempt to use the frame of the pump as support for the pulling force. 14. Use a wheel puller to pull the crosshead pin bearing inner races from the crosshead pins. Reliefs are machined into the head of the cross- head pins to permit the puller bars to engage the inner races. D. INSTALLATION 1, Carefully clean and inspect all parts for damage and wear, replace if necessary. 38 2. Install the crosshead pin bearings in the connecting rods. Use a hy- draulic jack and puller bar arrangement to press these into place. When in place the bearing must be horizontally centered in the eye of the connecting rod. 3. Install the upper crosshead guide using the guide retainers, hex head capscrews,* and lockwire. 4, Install the lower crosshead guide using the guide retainers, hex head capscrews* and lockwire. 5. Oil the upper and lower guides; place the center crosshead in the pump, and with the end of the connecting rod supported on a block of wood to keep it from interfering with the crosshead. Move it forward and back to be certain that it is not binding. 6. Install the crosshead extension rod with its capscrews* and locking wire 7 Install the center diaphragm support. Refer to DIAPHRAGMS in this publications for specific instructions. 8. Use a telescopic gauge and outside micrometer to determine the posi- tion of the crosshead extension rod inside the opening in the dia- phragm support. The readings must be taken with the crosshead in the forward, center, and back positions. —_——— *Torquing values will be found in the APPENDIX of this publication,Crossheads D. INSTALLATION 9. Add shims beneath the lower crosshead guide to bring the crosshead extension rod into the center of the opening. The shims must be installled to obtain true centering throughout the entire distance that the crosshead will travel in the crosshead guides. 10. Add shims on top of the upper guide to reduce the clearance between the top of the crosshead and the upper guide to .015" to .025”, feeler gauge is used to measure this clearance 11. Place the crosshead pin bearing inner races in a vat containing 15% soluble oil in water and heat to approximately 200° F, When heated place these races on the crosshead pins. 12. Center the crosshead end of the connecting rod in the center cross- head and install the crosshead pin, Puller bolts with a “strong back” or plate and a hydraulic jack may be used to force the crosshead pin in the crosshead. Install the retaining plate, capscrews*, and locking wire, 13, Place blocks of wood between the lower crosshead-guides and the eyes of the two outer connecting rods (these are to protect the guides when the shaft assemblies are rotated to gauge the “run-out” of the center cross— head assembly.) 14, Place two dial indicators on the diaphragm support. Position one of the indicators to read the vertical and one to read the horizontal “run-out” of the crosshead extension rod. Rotate the shaft assem- blies by hand using a socket or end wrench on the jackshaft exten- sion moving the crosshead forward and back. Take readings from the dial indicators and if the differential “run-out” for the complete stroke length is more than .010”, adjustments are necessary. If the vertical “run-out” is excessive, make adjustments as outlined in above paragraphs 7, 8, and 9. If the horizontal “run-out” is excessive, check to be certain that connecting rod is not contacting the crosshead. If contact is being made, check the crosshead pin bearing installation in the connecting rod. "In some instances it may be necessary to use a heavy brass bar to “bump” the connecting rod away from the contact pois NOTE: An improperly installed crosshead extension rod may give a false reading on the dial indicators. 15. Follow the instructions in the foregoing paragraphs 4 thru 12 to in- stall crosshead assembly “C”, then follow these same instructions to install crosshead assembly “A”. ST *Torquing values will be found in the APPENDIX of this publication. NATIONAL OILWELLJ vations OU WELL ae Crossheads D. INSTALLATION 16. Install the diaphragm assemblies. Refer to DIAPHRAGMS in this, publication for specific instructions. 17. Install the piston rod extensions and the extension rod clamps. On the 1400 and 1700 horsepower units, install the liner, and liner re- tainer nut prior to installing the extension rod clamp. ‘Refer to PIS- TON AND LINERS in this publication for specific instructions. 18, Install the crosshead inspection doors and gaskets. 40| NATIONAL OILWELL Connecting Rods ‘The Connecting Rods require very little attention since they have no ‘wearing parts and are heavily constructed. 41 (1) Connecting Rod (2) Connecting Rod Cap (8) Connecting Rod Bearing Retainer (4) Eccentric Bearing (5) Eccentric Bearing Retainer (6) Oil TroughNATIONAL OLLWELL que F Connecting Rods A. GENERAL ‘The connecting rods are marine type (enclosed eye at crosshead end, and with separate cap at crankend). They are rigid in construction and de- signed to accept replaceable parts at the wear points, i.e., eccentric bearing at the crank end and erosshead pin bearing at the crosshead en B. MAINTENANCE 1. Be certain that the lubrication system is properly maintained to insure lubrication of the crosshead pin bearing and the eccentric bearing. 2. Keep the connecting rod cap securely in place. 3. Keep the connecting rod oil trough securely in place. C. REMOVAL 1. The connecting rods cannot be removed from the pump unless the crankshaft is first removed. For ease of servicing the two outside connecting rod assemblies are generally removed with the crankshaft, and the center connecting rod (less the cotter pins, bolts, nuts, cap, 42 and oil trough) remains in the pump. Refer to CRANKSHAFT in this publication for specific instructions. 3. Provide support for the center connecting rod, and balance it with the crosshead assembly, then remove the rod and crosshead, as an assem- bly through the rear of the pump frame. 4, Remove the crosshead pin retaining plate, pin with inner bearing race, and crosshead from the center connecting rod, then pull the crosshead pin bearing from the connecting rod. Refer to CROSSHEADS in this publication for specific instructions. 5. With the crankshaft assembly removed from the pump, and properly supported (the connecting rods must also be supported), remove the oil troughs, cotter pins, nuts, bolts, and caps from the two outside connecting rods. NOTE: The connecting rod caps are matched with their respective connecting rods and are punch marked with identi- fying numbers. Be certain that these caps are not mixed, and when re-assembled are placed in the same relative position from which they were removed 6. Remove the crosshead pin bearings from the two outside connecting rods. Refer to CROSSHEADS in this publication for specific instrue- tions. 7. Remove the connecting rod eccentric bearing retainers from the con- necting rod caps. SSSF ATION AL OIL WELL Connecting Rods Cc. REMOVAL 8. If the eccentric bearings (connecting rod bearings or crankpin bear- ings) are to be removed, refer to CRANKSHAFT in this publication. D. INSTALLATION 1. Carefully clean and inspect all parts for damage and wear, replace if necessary. 2. If the eccentric bearings (connecting rod bearings or crankpin bear- ings) have been removed, refer to CRANKSHAFT in this publication for installation instructions. 3. Install the connecting rod eccentric bearing retainers in the connecting rod caps. 4, Install the crosshead pin bearings in the eye of the connecting rods. Refer to CROSSHEADS in this publication for specific instructions. 5, Install the crosshead, crosshead pin with inner bearing race, retain- ing plate, capscrews*, and locking wire on the center connecting 3 rod. Refer to CROSSHEADS in this publication for specific instruc- 4 tions. 6. Lubricate the upper and lower center crosshead guides. Install the center connecting rod/crosshead assembly and move it forward in the pump. Exercise care during this installation to prevent damage to the crosshead guides. Place a block of wood between the connecting rod and the lower guide to prevent damage to the guide. 7. Using the connecting rod caps, bolts, nuts*, and cotter pins, install the two outer connecting rods on the eccentric bearings. 8. Install the oil troughs on the two outer connecting rods. 9. Install the crankshaft with the two outer connecting rods. Refer to CRANKSHAFT in this publication for specific instructions. 10. When installation is complete as instructed under CRANKSHAFT in this publication, install the crosshead extension on the center cross- head, and complete the installation as outlined under CROSSHEADS in this publication. ny *Torquing values will be found in the APPENDIX of this publication.