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Before placing this equipment in operation, certain basic rules of safety should be observed. It should be noted that no sofety rules and no amount of safety equipment will make operating this equipment safe, unless the operator enforces the rules and proper uses of the equipment. MACHINE OPERATION 1. Only responsible persons, trained to do so, should operate this equipment. 2, Be sure all guards and covers are in place and secured before starting the equipment, 3. Moke certain all personnel ore clear of the equipment before starting. CLEANLINESS AND SERVICE 1. Periodic cleaning of the equipment mey reveal potential mechanical trouble spots such as loose or missing bolts, fittings, broken lines, etc. 2. Keep the area around the equipment clear of loose tools, trash, extraneous matter, etc. 3. Shut the equipment down before servicing or cleaning unless the service work requires the equipment be operating. 4, Allow only an experienced mechanic to service the equipment. 5. Ifa mechanical problem or deficiency is found, correct or report it before continuing operati 6. Before working under or between components that are suspended by hoists or slings, securely block or crib them. 7. When working in an area of potential head injury, wear an approved safety helmet. 0 | During most raising operations, maintain slack inthe belts between pump drive sheave on compound and pump sheave on rig driven pumps. This will prevent bending or breakage of the compound pump drive shaft from sub-structure movement during mast raising operations Many pump parts are heavy or difficult to handle. Plan lifts ond moves carefully to avoid severe personal injury. Provide sofe supports for disassembled ports.} | -— This manual has been prepared with the intention of supplying the user with o valuable service tool. Before placing the mud pump in service, study this manual thoroughly. Your familiority with the contents will prove o great aid in performing any service work on the pump correctly the first time ond os quickly as possible, A general check of all equipment shipped should be mode immediately upon delivery by qualified person- nel. Pay particular attention to those parts which were unprotected in shipment ond susceptible to damage. Toke into consideration any unsatisfactory conditions thot ore not immediately apparent from surface inspections. Immediately correct any damage prior to installing the equipment. Small, separately packed items, should be inspected for damage and missing parts. Safely repack these items, after inspecting them, until proper installotion procedures are taken. INTRODUCTION SKYTOP BREWSTER COMPANY mud pumps are de- signed to allow maximum flexibility in the choice of foundation material. In the selection of o foundation consideration must be given to the tremendous ‘amount of torque created by the pump and to the ambient soil conditions. What ever foundation material is selected, assure sufficient access space to all sump drains, access panels, and lube oil equip- ment The SKYTOP BREWSTER COMPANY recommends the user consult Section J of the “I.A.D.C. MANUAL” for further instructions on the care and maintenance of triplex mud pumps. For the soke of clarification of terminology in service work or ports ordering, use the diogram provided below to differentiate between RIGHT, LEFT, FRONT, ‘ond REAR of the pump. RIGHT sap a o 5 ° FRONT KH: lo REAR (FLUID END) Q) (POWER END) So} a - 7 LEFT »y —a DIMENSIONAL SPECIFICATIONS DIM. B- 1100- T _ us. METRIC are B | s-31 c 2 —136:2em—_ _124.1em B-1300-T METRIC “ATA Tom 224. 9emn 253.2em 179.4em Tate 5x 1.9m 721.590em 21.580¢m 120.7em 3).8cm 91.4em “179.7em_—_ | B-1600-T | | | METRIC a74.7em —179.7em 224.9em 252,6cm 74em Tate 5 x 1.9em 21.590«m 121.580em 120.7em~ PERFORMANCE DATA | pot | —+ —_7" x10" _ {100 40 sia — Tyo se 1.000 8s Dischorge Connex 1 4 __t Suction Connection Piston Rod Size. _APIHSA4 —t Valve Size _ APL HS Gece Ratio 4.4641 st, Weight™ 6,750 Lbs | _16,670Kas. “Weighs include cronkcove oil ad do not include drive sheove 8-1100-T a _ _ [smokes Tuo | 190 | 120 wo | 9% | 6 Pressure:-Volume |_Per Minute ff —j—_| Horsepower Chart* | rox | 943 706 | 707 | 629 : ot _ [io Discharge Output. Pressure Rating | Gollons per Ovtput-Gellons Per Minuto |e Revolution | — ee 5.00 700 | 450 [400 431 603. | | 431 | 367 | 3a 367 | 514 | 477 | 440 | 403 | 367 | 30 | 293 3.08 433 | aor | 369 | 338 | 308 | 277 | 247 2155 357 | 331 | 306 | 280 | 255 | 229 | 204 2.07 290 | 268 | 248 | 227 | 207 | 186 | 165 . 1.63 228 | 22 | 195 | 179 | 169 | 146 | 130 Strokes [ airs, | am | wo | 1m | | » | | 0 4 Inpet I Horsepower | 1at0 | 1192 | 1088 | 975 | ser 758 | 620 Rat { i Output: Gallons per Output-Gollons Per Minute “| Revolution | 6.00 720 | 660 | 600 | 540 | 480 5.17 620 | 569 | 517 | 465 | a1 in| Bo | Be | | sy | ass 370 | 440 | 407 | 370 | 309 | 296 3.06 367 | a7 | 306 | 275 | 245 248 | ave | 273 | 24a | 223 | 198 - _ ise | 205 | 2x6 | 96 | 176 | as7_ | 8-1600-T 100 90 ] 80 power Chart 1333 1200 | 1067 933, 800 — | __| Discharge | Pressure Reting | utput-Gallons Per Minute (Average) | Revolution | een | saa ~—«00~«| S720 [660 | 00 | Sad] 480) 420 | 80 on | 3960 517 go | 569 | 517 | 465 | ata | 362 | 310 6 4664 aa 529 | aes | aa | 397 | 353 | 309 | 265 5% 5000 370 aa | 407 | 370 | 339 | 296 | 259 | 22 5 5000 3.06 367 | 337 | 306 | 275 | 245 | 214 | 188 MA 5000 2.48 28 | 273 | 248 | 223° «198 «| «174 | 149 a __ 5000 1136 25_| 26 | 196 | 176 | 157 | 197 | 18SHEAVE INSTALLATION (Where Applicable) Your triplex mud pump is provided with o keyed pinion shaft for power input on either end of the shat, or both ends. Prior to instolling the sheave, clean the pinion shaft and sheave hub bore. Inspect the keyway ‘and key for burrs and remove any found. The key may be installed by positioning it in the keyway ond lightly topping it into place using a block of wood and a hammer. Coat the pinion shaft with a clean white lead or heavy grease. The hub and sheave may be installed {08 a unit with the sheave loosely bolted fo the hub, or, the hub may be positioned on the shaft and the sheave then bolted securely into position. To assure proper positioning of the hub/sheave assembly on the shoft, mark their position on the shaft before remov- ing them ‘A means for aligning the pump sheave to the power source sheave, and adjusting drive belt tension, must be furnished. Proper alignment will insure the usable service life of the V-Belts, Due to the inequality of V-Belt length, run the belts at medium tension. This will allow the belts to equalize under operating tension. FLUID END The fluid end should be disassembled following the “FLUID END MAINTENANCE” procedures provided in this manual. All internal parts should be thoroughly cleaned with non-residual industrial solvent and dryed. Reassemble as described in the “FLUID END MAINTENANCE” section, SUCTION LINE Emphasis must be placed on providing a correctly sized and placed suction line. The suction connection provided is a flange with an 8" pipe (B-1100-T) or 10 pipe (B-1300-T ond B-1600-1) for welding directly to the ‘customer's suction line. This weld MUST BE AIR TIGHT. The suction line between the pump ond mud tank should be as short as possible, When reducing suction line size, use only eccentric reducers 10 prevent cir pockets in the line, At least one section of suction line should be hose. This will reduce transfer of pump vibration and reduce wear on related components A strainer should be installed in the suction line to prevent debris from being drawn into the fluid end. It must be checked frequently ond cleaned whenever, necessary. When installing the suction manifold, insure that the mating faces of the fluid end and manifold are smooth ond free of defects. Inspect the "O" Ring channel for smoothness and the “O” Ring for cuts or distortion. be checked for tightness. INSTALLATION Install the copscrews finger tight on oll studs before moking-up tight using the triangulation method at each flange. DISCHARGE MANIFOLD The dischorge manifold is provided with a 4” - A.P.L 5000 Ib. flange connection (8-1100-T) or a 5” - A.P.L 5000 Ib. flange connection (8-1300-T and 8-1600-1), The manifold is attached to the steel fluid end sections with four heavy hex nuts for each fluid end section. ‘An "O" Ring is used to seal the connection between the discharge manifold ond fluid end sections. When installing the discharge manifold, insure thet the mating faces of the fluid end and manifold are smooth ond free of defects. Inspect the "O” Ring for cuts or distortion. Install the nuts finger fight on all studs before making-up tight using the triangulation method ot each flange. Use make-up torque for grade 8 bolts shown on page 14. RELIEF VALVE Check the relief valve to verity the proper setting. This setting should be no greater than 30% above the working pressure of the liner size installed in the pump. NEVER operate the pump without o relief valve, doing so endangers the lives of the erew and will seriously damage the fluid end in the event of a severe pressure surge or line blockage. PRE-START-UP CHECKLIST Before placing the pump in operation for any reason: —Remove all inspection doors and check for con: tamination ond obstructive objects. Lubricate the pump as outlined in the “Lubrica- ion” section of this manual and on the specifica tion plate on the pump frame. Check the tightness of all pump, fluid end, ond ‘anchoring bolts —Rotate the pump by hand to assure free move- ment. Verity the correct rotation of the pinion shaft This is to assure proper lubrication of the power end. The correct rotation is indicated by the top of the pinion shoft turning away from the fluid end. PRIME THE FLUID END by removing the discharge valve and filling each cylinder with water. This is ‘9 must as it lubricates the pistons and liners Alter the pump has been in operation for one day, and ‘gain after ten days, all nuts on the fluid end shouldPOWER END (Ret. Pgs. 25 & 26) SKYTOP BREWSTER COMPANY triplex mud pumps are internally lubricated by 0 pressurized lubrication sys tem. In this system filtered pumped, by on internally mounted oil pump, to the crankshaft main bearings, pinion shaft bearings, and crosshead cessemblies. A pressure gauge (46), located on the front wall of the pump frame, measures oil pressure in the lubrication lines. The pressure will fluctuate according 10 the pump operating speed. Should any radical changes in pressure occur the pump should be shutdown and the cause of the change investigated. Never operate the pump with less than 5 P.S.I. pressure. The relief valve fon the lube pump should be set at 40 P.S.1 is important thot the proper crankcase oil level be maintained. The oil level may be checked with pump idle by following the prescribed procedures. Allow the pump to remain idle for a five minute period before checking the idle oil level. This will allow the cil to equalize ond give a “Full” reading at the top mork of the dipstick. Oil, as needed, moy be added through the inspection cover on the top of the power end. Once a week, remove a settling chamber drain plug to drain any accumulation of water. The oil should be routinely changed after six months oF 2,000 hours of operation, or if the oil has become overly contominated. Replace the oil with approved lubricant. At each oil chonge, remove the breather cop and clean or replace the copper wool filter. Clean the magnets on both sump drain plugs. Remove the crosshead covers ond settling chamber drain plugs. Clean the settling chamber beneath the crosshead of all sludge and debris. To obtain an oil sample, or to drain the sump, a magnet drain plug is provided at the base of both dipstick sheaths on the sides of the power end (see Fig. A.). A lubricant filter screen is located in the power end sump adjacent to the oil pump. This screen should be cleaned on a regular basis or if a significont pressure drop is noted ‘cROssHEAD covER — PINION SHAFT wspecrion cOvER \ SETTLING ceaweer Sean Pus ovpstick~/ ‘SUMP ORAIN= ~~ LUBRICATION \Cmaun BEARING COVER, a PISTONS and RODS (Ref. Pgs. 27-30) The pistons and liners, are cooled and lubricated by either a mechanical or electrical pump system. Both systems direct clean water onto the pistons and liners in a regulated flow, adjusted by a valve located ad: jacent to the stuffing box. Water running off accumu- lates ina compartmentalized sump, located below the piston rod, where it is recirculated by the lube pump system. This sump collects effluent and solid woste which might otherwise be recirculated through the lubrication system. The sump has drains on both sides of the pump to allow flushing out any residue and should be flushed ot each oil change. Keep the flow of water only in quantities needed to keep the piston rubber cool and lubricated, and the 1er well washed. Cleon water should be used. LUBRICANT CAPACITIES 1100-T —8-1300-T —_B-1600-T Crankcase Oil —95Gol. —*165Gal. 165 B00 Liters 625liters 625 Liters Piston Lube 70Gol. _80Gal. 80 Gal (Clear water) 265 Liters 303Liters 303 Liters RECOMMENDED CRANKCASE LUBRICANT GRADES Ambient Temperature +30°F, To +125°F. Use 0°C. To — 52°C. AGMA #6 EP Ambient Temperature 20°F. To + 40°F. Use 90°C. To + 5°C. AGMA #4 EP SSPROIFICATION PLATE \ At Soischarce: MANIFOLD V \ suction. MANIFOLD SUMP pain’ LINER WASH SUM Fig. AOPERATION SKYTOP BREWSTER COMPANY triplex mud pumps are quality built machines, and a good maintenance program will ‘ossure many years of dependable service. Scheduled inspections of the following points, during pump operation, may prevent personal injury or expensive down time. FLUID END 1, SUCTION LINE—The slush pump transmits © con- siderable amount of vibration through the suction line. This vibration may eventually loosen the suc- tion line flange connections. Always keep these connections made-up airtight. 2. CYLINDER LINERS AND SEALS$—The scrubbing action of the piston rubber and the abrasiveness of the drilling fluid will eventually wear the liner out, Damaged packing may cause fluid end wash- outs. Each cylinder head flange has 0 weep hole at the bottom centerline. A flow from this hole indicates cylinder head looseness or domoged cylinder head gasket. If leak is noticed, tighten the cy- linder head until the leak stops. If the leak persists then the pump must be shutdown and the cause identified, When replacing the liners, exercise care in han- dling them to avoid damaging the sealing surface of the liner. If the liners ore to be stored for an extended period, coat them with grease to prevent corrosion. Always replace cylinder head gaskets and liner seals when replocing the liners. When tightening down on the gaskets and seals, use only as much pressure as is necessary to prevent leakage. Over-tightening the seals will only reduce their service life 3. VALVES, SEATS, AND GUIDES—Worn valves, ats, and guides will seriously impair the effi tency of the pump. Worn valve guides do not allow proper seating of the valve, be aware of their condition and replace os necessary. Do not mix worn valves or seats with new valves or seats. Replace the seoling element on the valve before it leaks to extend seat life. 4. VALVE POT COVERS AND GASKETS—Look for leaking fluid around the valve pot covers. If leak: age is detected, tighten down on the cover until the leaking stops. If the leck persists then the gosket must be replaced. 5. STUDS—Reploce ony stripped or damaged studs ‘at first opportunity. The load which the damaged stud should be bearing is transferred to those ad- joining studs which could cause their premature foilure. Refer to torque value chart for proper torques. PRESSURE RELIEF VALVE—Check the valve to ‘assure proper operation and that it is properly set. 7. PULSATION DAMPENER—Periodically check the tightness of all bolts ond check the charge on the bladder. POWER END 1. PISTON ROD LUBE Ol PIPING_Drilling fluid ond sediment deposits must be flushed from the com: portmentalized lube oil sump. Keep the oil clean fo lessen the wear on the lub oil pump, piston, nd liner. 2. CROSSHEAD EXTENSION--Keep the rod made-up tight at all times to the crosshead body. Keep the piston rod clamp tight at all times and replace when it fails to secure the crosshead extension ‘and piston rod tightly. POWER END STUFFING BOX—The stuffing box prevents drilling fluid from entering the power ‘end and the power end lubricant from leaking out. The packing should only be tightened enough to prevent leakage. Over-tightening will only accelerate wear on the packing MAINTENANCE PINION SHAFT (Ref. Pgs. 19 8 20) The crankshaft must be removed before the pinion shaft con be removed or installed. The pinion shaft assembly may be removed from either side of the pump frame if the proper hoisting ‘equipment is available at the well site. Because of the ‘awkwardness of handling the weight of the shaft in the close quarters of the pump frame, CAUTION is edvised to prevent personal injury and damage to the pump. To remove: 1. Support the shaft with ti weight off of the be Disconnect the oil lines ot both ends of shaft. 3. Opposite the pump side through which the shoft —will be pulled, remove capscrews (32) and pinion bearing retainer (26) by using the jacking holes provided. Heat the spacer (27) carefully by torch ‘and remove. Be careful not to burn the shaft, 4. On the pump side through which the shaft will be pulled, remove the copscrews, retainer, and spacer as described in paragraph 3. Remove cop- screws (30) on the bearing carrier (25) and use two of them in the jack holes to remove the carrier. The shaft may now be pulled for service. To install pinion shaft, reverse removal procedure shown above. 1. Clean the contact surfaces of the bearing carrier (25) and retainer (26) and install new gaskets (35, 36) 2. The carrier and retainer have “Top” cast on them. Insure that these pieces are installed with “Top” up. 3. Before installing the retainer and seals (28), opply a light coat of lubricant to the spacer (27) to ease sliding the seals into position. 4. Tighten copscrews (30, 32) by the triangulation method and replace safety wires, Replace lube oil lines. CRANKSHAFT (Ref. Pgs. 178 18) To remove the crankshaft from the pump chassis: 1. Determine, by looking at the center crosshead, from which side of the pump the center crosshead wrist pin will be removed. Remove the wrist pin from the outside crosshead (on the side the center crosshead wrist pin will be removed) using the jacking holes provided. Follow the instructions under "Crosshead Assembly” for wrist pin re- moval. Slowly back the connecting rod out of the outside crosshead allowing it to rest on a hardwood block placed on the lower crosshead guide. These blocks are important in that they protect the guides from scarring by the rods. Push the outer crosshead forward to gain access to the center crosshead Follow the above procedures to remove the center crosshead and other outer crosshead. 2. Disconnect the lube oll pipes from the main bear- ing housings and remove the housings. Remove cil pump to avoid bending oil pump shaft during crankshaft removal. (Ref. pg. 25 & 26) Slings should be positioned on the crankshaft so MAINTENANCE thot it will remain level while being hoisted. Lift- ing holes are provided in one eccentric and the ‘gear flange. The connecting rods should be sup- ported with slings to prevent their damaging the crosshead guides during removal. 4. Raise the crankshaft slightly to take the weight off the main bearing carriers. Rotate the carriers 90° so that the flat surface of carrier is verical and facing the rear of the pump. Ease the shoft slowly out of the frame and rest it on a mat of wood planking to protect the gear teeth. Support the assembly securely Many pump parts are heavy or difficult to handle, Plan lifts and moves carefully to avoid severe personal injury. Provide safe supports for disassembled parts. The crankshaft ossembly must be removed to install new main and connecting rod bearings. To remove moin bearings: 1. Remove the bearing retainer and shims carefully setting them aside as to differentiate between which sets go on the pump right or left side. 2. With an appropriate puller, remove the main bearings. If the beorings are to be re-installed, protect them from contamination and note from which side of the pump they come. DO NOT re- verse the sides from which the bearings were originally installed. ALWAYS replace the bearings in their original position. To install main bearings: 1. Clean the inside diameter of the bearing race and the crankshaft bearing seats with a non-residval industrial solvent. 2. Seat the bearing hand tight onto the shaft. With o depth micrometer, measure the distance from the ‘end of the bearing to the end of the shaft 3. From the dimension gained in the previous step, subtract .072" (B-1100-1) or .086” (B-1900-T and B-1600-T). This will determine the required shim thickness. 4, Install the shims ond the bearing retainer, and thon bolt the assembly down tight. With the bear-nee ee ee instolled on the crankshaft, check the diamet- rical clearance at the bottom of the bearing. The tolerance should be .0035" to .0075”. Replace the safety wires on the retainer capscrews. CONNECTING ROD BEARING To remove or instoll bearings, the crankshaft must be removed from the pump frame. ALWAYS install center connecting rod FIRST during re-ossembly. To remove 1. On the center and outer connecting rods remove capscrews (15) and bearing retainers (11). Cai fully slide the outer rods off the crankshaft and set aside. Do not confuse from which side the rods 2. The bearing inner races from the outside rods must be removed carefully by heating before the center rod con be removed. Exercise caution in doing this to prevent burning the bearing seats on the crankshaft. Once this is accomplished, the center rod moy be removed by following the same instructions os the outer rods. 3. Remove the center rod inner bearing race by care- fully heating ond then sliding it off it’s seat ond ‘over the outer rod bearing seat. To install: 1. Clean the inside diameter of the connecting rod ‘ond the bearing seat on the crankshaft with @ non-residual industrial solvent. 2. Carefully heat the rod with 0 torch until the inside diameter is hot to the touch. 3. Slide the bearing outer race in until it rests evenly on the shoulder. Install the bearing retainer (10) ‘and capscrews (15). 4. Carefully heat the bearing inner race with a torch until it is hot to the touch. Keep the torch moving to prevent localized heating. Slide the inner race ‘over the outer bearing seat and onto the center seat until it rests evenly against the shoulder. 5. Alter the inner and outer races have cooled and set, carefully slide the rod onto the inner race. 6. Secure the rod to the crankshaft by installing the beoring retainer (11) and capscrews (15). Replace all safety wires. 7. On the outer connecting rod bearings, install the bearing retainer (11) and capscrews (15) and tighten. These retoiners act as shoulders for the inner races. Install the bearings as directed obove. MAINTENANCE CROSSHEAD BEARING (Ref. Pgs. 21 & 22) To remove the bearing from the connecting rod, care- fully drive it out using a hammer and brass drift. Be careful not to damage the bearing bore Before installing o new bearing in the rod, inspect the bore for nicks or burrs, and clean the bore with @ non-residual industrial solvent. Do not remove the packing lubricont from a new bearing unless it is soiled. Heat the eye of the rod to 300°F. with a torch, moving the torch constantly to prevent localized heat: ing. Use a “temple stik" to determine rod tempero ture. Position the becring in the bore so that the ends of the bearing are flush with the sides of the connect. ing rod. Hold the bearing in position until the rod cools. DO NOT USE WATER TO COOL THE ROD. CRANKSHAFT INSTALLATION 1. Clean the beoring seats in the frame with a non: residual industrial solvent ond inspect for any sur- face nicks or burrs. Apply a light lubricant. 2. Hoist the crankshaft assembly, support the rods with straps. Rotate the bearing carriers so that the flat surface of each is vertical and facing the rear of the pump. This provides the necessary clearance for the carrier to slide into the seat. 3. Slowly, and very carefully, lower the assembly into the frame until the rods can be inserted into their respective crossheods. Be certain that the lower crosshead guides ore protected with hard: wood blocks or similar protective bumper. Guide the beoring carriers into the seats. The bearings must not bind on the seats, as this might damage the carrier or seat surfaces, 4. Install the main bearing housings, which ore stamped “left” and “right” on the top side of each. These housings must not be interchanged. Re- place the safety wires, and reconnect lube oil lines. 5. With the crankshaft installed and the bearing re- tainers secured in their respective positions, check the bearing rollers to assure that each row of rollers in each bearing is equally loaded. The same number of bearing rollers should be tight on both sides of each bearing. 6. Replace the oil pump and clean or replace the lubricant filter. (Ref. pg. 25 & 26). CROSSHEAD ASSEMBLY (Ref. Pgs. 21 & 22) The left and right crossheads must be disconnected from their connecting rods and pushed forward to gain access to the center crosshead.To remove: 1, Position the crosshead in the moximum back- stroke position. 2. Loosen bolts (21) and nuts (22) and remove the piston rod following the instructions in the fluid ‘end maintenance section, 3. Remove the battle disc (24). 4, Remove the cover plate (8), crosshead extension packing set (18), packing sleeve (17), and “O” Ring (20). 5. The stuffing box (7) end stuffing box plate (26) may now be removed. The crosshead extension (6) can be token out by removing the six allen head copscrews (14). 6. Center the crosshead in the door opening. To re- move the wrist pin (4), remove four copscrews (13) and place two of them in the jackholes pro- vided in the wrist pin retainer plate (5). Apply equal torque to the capscrews until the pin breaks loose, Mark the pin to identify which crosshead it mates and set it aside. 7. Place a block of hardwood under the connecting rod to prevent damaging the lower crosshead guide. While supporting the connecting rod. rotate the pump to pull the rod out of the cross- head. Ease the rod onto the hardwood block when it clears the crosshead. 8. The crosshead may now be slid forward out of the crosshead compartment and hoisted out of the pump frame through the topside openings. To install: 1. Replace the crosshead into the frame. A little lub- Ficant applied to the lower guide will help in positioning the crosshead. 2. Clean the inner race of the connecting red bearing with a non-residval industrial solvent and inspect it for nicks and burrs. Insert the rod and center it in the crosshead, Place the wrist pin through the crosshead and wrist pin bearing. Be careful not to damage the bearing. Set the wrist pin by placing a block of hardwood against the exposed end, and striking it with @ hammer until it is seated. 3. Replace the retainer plate and bolt it securely into place. Tighten the capscrews with uniform torque Using the triangulation method. Replace the safety wire. 4. Replace the crosshead extension and capscrews, tightening the capscrews using the triongulation method. Replace the safety wire. Replace the MAINTENANCE stuffing box plate and gaskets, and the stuffing box and gasket (25) 5. Apply a coat of grease to the crosshead extension ‘nd slide on new packing set and packing sleeve. Examine the “O" Rings for cuts or weer and replace if damaged. Install cover plate and secure with capscrews, 6. Slide baile disc into position and reconnect cross- head extension to the piston rod with piston rod clamp. With the guides and crosshead installed, measure the clearance between the top surface of the crosshead ‘ond the surface of the upper shoe. This distance should be .010" to .020.” CROSSHEAD GUIDES (Ref. Pgs. 21 8 22) To remove the upper and lower crosshead guides, remove the capscrews (12) being coreful to support the upper guide to prevent its falling During normal pump operation, the lower guide will take the brunt of the wear imposed by the motion of the crosshead. In some instances, the upper and lower guides may be reversed, but only if the existing upper guide hos a smooth, unblemished surface. it both guides are worn or damaged, they should be replaced with new units. Install the crossheod guide capscrews with "Locktite.”” The horizontal center lines of the crossheads must match the center lines of the fluid end frame bores for the pistons to run true to the liners. To check alignment: Shim crosshead guides to center the end of the piston rod in the pump frame front plate bore. Using o diol indicator with a flat tip against the top of extension rod, slide the crosshead to determine if the rod is running horizontlly or at an angle. A shim should be placed between the crosshead and upper guide ot the rear of the crossheod to prevent the crosshead from tipping and giving erroneous readings. Maximum allowable deviation from horizontal is .002” measured cover six inches of crosshead travel. Shim as required to meet allowable deviation. Check to see if piston rod is still centered in pump frame front plate bore. if not, repeot the procedure until all requirements are met. After crosshead is properly aligned, remove the shim between the crosshead and the upper guid Failure to remove this shim will result in damage to the pump. Ht shimming is required, beor in mind that the minimum clearance between the top of the crosshead ond upper guide is .010." The shimming material should be steel shim stock and the strips should be long enough to completely cross the guide.ee =~ MAINTENANCE FLUID END The SKYTOP BREWSTER COMPANY fluid end consists of three forged steel fluid end sections (with valve and liners) discharge monifold, and @ suction manifold either one inlet or alternate two inlet, FLUID END BLOCKS (Ref. Pgs. 23 & 24) The fluid end blocks make-up metal-to-metal to the power end with heavy hex nuts and studs. The blocks are aligned with the stub rod centerlines by a shouldered recess in the power end front plate for each block The mating surfaces on the fluid end blocks and the power end frome must be clean and free of ony defects to insure an aligned installation. Tighten the hex nuts using the triangulation method ond the applicable torque value shown on page 14 LINERS To remove: 1. After removing suction valves (see "VALVES AND SEATS” section) loosen and remove capscrews (82), liner ring (19), ond liner retainer collar (20). 2. Pull liner out through the fluid end block and re- move liner gasket (27). Liners that are to be used again should be coated with oil to protect them ogainst rust To install: 1. Thoroughly clean the liner inside, and out, remov- ing any preservatives. Cleon the machined sur- faces of the liner bore and inspect for nicks, burrs, or washouts. 2. Apply a light coat of lubricant to the outer diometer of the liner and install new liner gasket (27). Coretully slide the liner into position making MAIN STEM - - CX. nur TOP WEDGE BLOCK. “ ——— sortom wence BLOCK 7 #7004 HEAD MECHANICAL WEDGE sure the liner lip makes flush contact with the fluid end block shoulder. 3. Install liner retainer collar (20) and liner ring (19). The capscrews on the retainer collar should not be over-tightened resulting in collar distortion. After the pump is operational these capscrews should be tightened only enough to prevent movement of the liner. VALVES AND SEATS (Ref. Pgs. 23 & 24) To remove: 1. Remove valve cover lock (4), valve pot cover (8), cylinder head lock (5). and cylinder head (9). 2. Remove the lower valve guide (10), with attached lower guide bushing keeper (11) and bushing (35), by tipping the top of the valve guide back ond re- moving. This will provide clearance for the top of, the valve stem to clear the guide bushing. Remove the suction ond discharge valves and springs. 3. To remove the valve seats, it is recommended that @ mechanical wedge or hydraulic valve seat puller be used. Using a torch to remove valve seats is not recommended because of the poten: tial of burning the valve seat taper. If a mechanical or hydraulic puller is employed, stem extension assembly is necessary to pull the suction valve seat. The discharge valve seats must be pulled before the suction valve seats. (Ref. Fig. 8) -= MAIN STEM UPPER ADAPTOR STEM EXTENSION LOWER ADAPTOR PLATE ere SNS sus STEM f ss PULLER HEAD SEAT tia we BS HYDRAULIC PULLERMechanical Wedge—Place the tool stem with upper adapter plate and stem extension through discharge seat cross-arms. Loy bottom wedge block over the stem, then wedge, top wedge block, and nut. When placing wedge, insure thot the flange studs are protected with cloth packing, Attach puller head, sub-stem and lower adopter plate to stem extension and suction seat cross- ‘erm and take up any slack in the assembly. Tight- fen _main ster nut by alternately striking the wedge with a sledge and forcefully tightening the main stem nut. The suction seat will pull free ond may be removed through the cylinder head flange. The discharge seat may be pulled by delet- ing the stem extension assembly and ottaching the puller head directly to the main stem. Hydraulic Pullers—Use the some type puller head ond stem as a mechanical wedge but a hydrauli jack is substituted for the wedge. When using this type puller make sure it is secured to the fluid end to prevent its falling when the seat breaks loose. 4. After the seats ore pulled thoroughly wash the seat decks and surrounding surfaces. Inspect the topers for cracks, washcuts, or roughness ond repair os necessary. Clean the tapers with a non- residual industriel solvent and protect them from ony contamination until new seats are installed. To install: 1. Remove ony rust inhibitor coating from the new valve seat with @ non-residual industrial solvent. Place the seat in the toper ond press firmly by hand. The seat should stick in the toper firmly with even contact between taper and seat around their circumference. If even contact is not made the seat should be carefully removed and the couse identified and corrected. 2. With the seat firmly placed in the taper, set it by placing an old valve on the seat and striking the upper stem with a sledge hammer. The hammer should bounce free if the seat set properly. DO NOT rely on pump pressure to seal the seat to taper, doing so may cause washcuts on toper and seat. 3. Install new suction valve and spring. Examine lower valve guide bushing for damage or wear. Wear should not exceed 1/16” clearance around valve stem. Replace lower valve guide and bushing keeper by tipping the top of the valve guide back and slip over valve stem. Lightly grease new cylinder head gosket (26) and install. Replace cylinder heod, threaded flange (with weep hole at bottom), and cylinder head lock. Inspect upper valve guide bushing for defects and wear as directed in step 3 above. Install new . MAINTENANCE ) valve. Apply a light coat of grease to valve pot gosket and install. Replace threaded flange, valve pot cover, and vaive cover lock. PISTONS and RODS (Ref. Pgs. 21-24) The piston and rod assemblies may be removed through the fluid end blocks by removing the cylinder head locks, cylinder heads, ond valves. Loosen bolts ‘ond nuts (21, 22) on the piston rod clamps and remove the clamps. The rods with pistons may now be slid out through the fluid end block. To remove the piston body ond rubber loosen and remove the splined nut using the splined wrench. Inspect the piston seat and flange on the rod for ‘excessive wear or washcut damage. Replace as necessary. toll new piston body and rubber: 1. Clean threads, rod end, and red flange thoroughly and apply a light coat of grease to these areas. 2. Lightly grease piston "O" Ring and place in piston “O" Ring groove. Seat piston squarely against rod flange. 3. Replace splined nut ond tighten os follows Piston with 1-1/2" or 1-5/8" hole—one man's weight on 3' splined wrench-cheater combination. Piston with 1” hole—one man's weight on 18” splined wrench, stall new piston rubber only: 1. Remove old piston rubber by driving loose the snap ring with 2 60 penny nail. The ring will peel off in a clockwise direction. Remove the piston re- tainer plate ond corefully pry the old rubber off 2. Clean the piston seat of all caked mud, rust, or piston fabric. Inspect piston body for wear or washeut damage. 3. Firmly push new piston rubber into place and in stall new piston retainer plate. Install new snop ring with short firm strokes of o hammer working in @ counter-clockwise direction. Once the snap ing is in place, check it by striking its circumfer- ence again with a hammer to assure it is seated well To install the piston and rod in the pump, grease the jon to ease installation. If the piston rubber is natural rubber do not use grease, but instead, use a solution of detergent used in drilling muds, or @ rig ‘washing compound. It may become necessary to use a timber and sledge hammer to drive the assembly into the liner after carefully starting the back lip in the liner. Replace piston rod clamp and tighten.MAINTENANCE PULSATION DAMPENER CHARGING INSTRUCTIONS 1. Remove the pulsation dampener gauge cover located at the top of the dampener. 2. Connect the charging hose to the dompener charging valve and to the nitrogen cylinder valve. 3. Open the dampener valve completely. 4. Open the nitrogen cylinder valve slowly, using this valve to regulate the flow fo the dampener. 5. When the desired pressure in the dompener has been reached. close the nitrogen cylinder valve. 6. Close the dampener valve. 7. Remove the charging hose from the dampener and the cylinder and replace the gauge cover. PRESSURE ] SHARGING DAMPENER CAXRcING Vecvarcine ‘ putsation Hose BAMPENER MUD PUMP STORAGE and PRESERVATION Prior to storing your mud pump for @ lengthy time, certain precautionary measures should be token to cossure the well-being of the pump and its components. 1, Drain the fluid end. 2. Unscrew the valve cover locks and remove the valve pot covers, springs, and valves. Thoroughly cleon each component and cot with rust inhibitor. 3. Apply rust inhibitor to all interior ports and sur- foces of the cylinder and valve areas after the fluid end has been drained, 4. Droin ond clean the piston rod lube sump. Coat exposed rods and crosshead extension rods with rust inhibitor. 5. Hang desiccant bags in each valve pot cover and in each liner cage and reassemble the fluid end components. Seal the suction and discharge flanges to prevent the entrance of moisture into the fluid end. 6. Release the nitrogen pressure in the pulsation dampener and remove it if the pump is to be transferred. Toke apart and clean the dampener ‘according to the manufacturer's instructions. Securely crate and tag the dampener to assure sofe transport Drain the power end main sump of all lubricant. Remove the crankcase and crosshead covers and clean the interior curfaces. Coat all surfaces with rust inhibitor and heng several desiccant bags. Replace the crankcase and crosshead covers, and then seal For storage in freezing temperatures, the above procedures will prevent any freeze damage to the fluid end.Mai BEARING 7 HOUSING RECOMMENDED L B100-t 6000 Bsco-r 8600 81600-7 10500 SAFETY WIRE MAIN BEARING HOUSING TORGUE -Fe-Lbs, Dry Boo 300 SAFETY WIRE 16-20 Gauge—Ensure thot wire is “pull- I TORQUE VALUES ing’ both copscrews In @ tightening MAKE-UP TORQUE VALUES FT. LBS. BOLT SAE SAE SAE GRADE GRADE GRADE GRADE 5 7 8 BOLT . SIZE DRY 5/16-18NC | 20-21 5/16-24NF_ 3/8-16NC T/6-14NC __1/16-20NF | L . V/2-19NC _1/2-20NF_ 192-120 9/16-12NC 140-150 9/16-10NF | 140.150 158-170 5/8-11NC 177-190 __5/8-18NF | 195.210 3/4-10NC 298-320 | 338-360 484.520 _ 599.580 744-800 e00-860 14-660 | _ 28.740 1042:1120 7ei-e40 | 1190-1260 893.960 818-280 1172-126 974.940 | 1999-1440 1004-1080 1042-1120 781-840 | 1469-1580 1023-1100 | 1699-1820 1265-1360 1-1/4. BNC 1098-1180 819.880 | 1859-1670 1126-1210 | 1777-1910 1390-1490 | ievarane | 1153-1240 886-920 | 1697-1760___—_1228-1920_|_1860-2000__—_1395-1500_ 1-9/8: ONC 1958-1460 1023-1100 | 1904-2080 1451-1560 | 2219-2980 1655-1780 vasev2nr | _1562-1680_——_1172-1260_ | 2213-2380 1655-1780__| 2530-2720 ___1897-2040_ 1.17 NC 1904-1940 1958-1460 | 2585-2780 1964-2060 | 2909-3160 2195-2960 1-1/2. BNC 1925-2070 1442-1550 (2734-2940 2046-2200 | 3125-3360 2134-2510 1:1/2-12NF 2046-2200 __1525-1640_| 2869-3100 2158-2320 | 9911-9560 2074-2660st) FRAME ASSEMBLY- B-1100-T “] Bt300-T/B-1600T = | eT eee ee — DESCRIPTION Frome Skid, Fluid End Stud, Breather Dip Stick Nameplate (B-1300-T/8-1600-T) Latch Assy.) Plate, Cover Bolt Gasket, Crankcase Cover Capscrew (Bolt Latch Ass'y.) er (Bolt Latch Ass'y, Copper (Bol oper ‘Assembly, Bolt Latch Nameplate, Rojation 2 | Gasket (Crosshead Cover) | 2 | Gesker (Moin Brg. Cover 2 Drive Screw 24 Capscrew a Pius, Pipe 8 Copscreve > = “Cover, Rod Lub. Tank — 3602-46-09 | —096031-46-01-5 1 036024-47-01-7_| _ 036031-47-01-3. 1; —Cover, Rod Lub. Tonk _ (036031-45-01-7 1 Tonk, Rod Lubrication16,19,20. SS. seo HAFT ASSEMBLY oo - fRe- A\ Vr, - Qe Ne - ‘ enmeee eee Tem PART NO. ary, | PARTNO. -_B-1300-T _———| ary. DESCRIPTION | 036032-02.01-5 | "Crankshaft (036032-11-01- __ Gear |__036032-08.01-2 | Rod, Connecting (036025-24.01-3, 036032-25-01-6 | _036032-44-01-7 __982020-09-61-6 8L— B-1600- me toe s__ | oecaron PART NO. | ary. [eee an079 | a Cenk xo1101.0 | I oor 036025.08.01.6 | [3 Rod, Connecting 7551010 | a esanoone [8 Bern, Eco 742 eearing. Mal 1 036032-14-01-0 _|__ Carrier, Main Brg, (R.H.) | 1 [oss 0r8 cove, Man Bg (sh) | Main Brg. Outer Race_| iner, Main Brg. Inner Race _| 2 2 2 3 iner, Ecc. Brg. Outer Race | Retainer, Ecc. Brg. Inner Roce Shim Pack, Main Bearing Nut, Flexlock { Bolt, Gr. 5 Hex Bolt, Gr 5 Hex Capscrew, Drilled HeadB-1100-T B-1300-T DESCRIPTION PART NO. . PART NO. | swear Seal, Oil ———— Key Copscrew, 5/8" | 036092-47-01.0 | - 7 |B-1100-T “B-1300-T / B-1600-T_ — DESCRIPTION PART NO. ary, Rod, Stub 036032-35-01-5 Box, Stuffing | 116458.-00-00-1 (036032-28-01-0 Capscrew, Ferry Head Copscrew, ‘Capscrew, Hex Heod Capscrew, Hex Heod 114347-00-00- 114348.00-00. 116457-00-00-3 Packing 116456-00-00.5 I Sot, Packing ~082020-04-61-6 (036025-52-01-8_ 036032-49.01-6 Strato Seal "Copscrew, Hex Head |4 37 44.43 4256 41 _B-1100-T | B-1300-T / 8-1600-T] PARTNO. | QTY. - 0 Te; ~1a007 7 Bion Brot | 819007 / 816007 | eerion Trem QTY.) PART NO. DESCRIPTION 4 oar 3a 8 7 7 083 " od 29 | { z A 2 |_Nut, NY-Lock, 4 af 3 2 Flonge, Valve Cover_ 3 | Cover, Valve Pot 5 31 4 2 | Tee. 2] Elbow, 90°(7 POWER END LUBRICATION a BS 37 38 44.43 25 SO ES 33 BB SB 7 28 32 45 32 33 29 19 10 13 13 30 12 18 18 Plan View Sect. "“A-A”Sect. "B-B" sae Sect. "C-C" 1 B-1100-T B-1300-T / B-1600-T rem Tr DESCRIPTION | PARTNO. — [ary. | PARTNO. | aTy, | Tube, Copper Elbow Tee. TeeMECHANICAL_—______j _* PART NO. B-1300-T / B-1600-T _ DESCRIPTION Pump, | Lube Oi ‘Sheove Key, = llahal|-LLfofoboboleefef-[-[-|-)-|-[-|9 x | | | { | | | | | { me) ela baladalafa (071018-24-09-71D SS sp 3 ss (— PISTON ROD LUBRICATION — ELECTRICALITEM B-1100-T 8-1300-T 7 B-1600-T PART NO. PART NO. ary. DESCRIPTION Plug, Sq. Soe, Reducer ng. Bronze Swing Check Face Thread (036024-46-01-9, (036031-46-01-5 Rod Lub, Tank _ (036024-47-01-7 (036031-47-01-3 Rod Lub. Tank (036031-45-01-7 Tank, Rod Lubrication o€ rdSKYTOP BREWSTER SERVICE CENTERS Requests for service and parts may be made by the customer, directly to the nearest Skytop Brewster Service Center in the United States ond Canada, Skytop Brewster Service Centers are staffed with trained personnel and carry parts inventory to meet normal requirements. Each service center maintains serial reference parts books, os well os unit files on equipment operating in its area. Parts ordered that ‘are not currently carried in service center inventory beor a related charge for shipment by motor freight, bus, oir freight or special truck. Freight is shipped cheapest way unless otherwise specified. Internation- al rates available upon request. SPECIAL SERVICES Firm or estimated quotations will be furnished on re- quest. Quotations requiring preliminary engineering will be invoiced ot current engineering rates. Engineering services required in special field rig-up; modification or wreck repairs will be billed at rate of $400.00 per day. All additional services supplied by someone other than Skytop Brewster, such as welding, steaming ond sandblasting, contracted for and supervised by Skytop Brewster, will be billed at cost plus 15% RETURN OF PARTS Authority from Skytop Brewster Service Manager must be obtained for the return of parts. Inspection of the material will be made before credit is established ‘ond all returns will carry an inventory restocking charge. No credit will be allowed on items not in cur- rent production. Special purchased material will carry only vendor's credits. Freight on parts must be prepaid to Skytop Brewster Service Center or as directed in return instructions. SERVICEMEN'S EXPENSES Expenses incurred by servicemen while in customer's service will be based on a total of all expenses to Sky- top Brewster. Charges will be made for each day or part of day. SERVICE INFORMATION TRANSPORTATION RATES Regular field service vehicle (pick-up) $0.50 per mile Service rates start when Skytop Brewster employee is assigned to the shop or field activity pursuant to the customer's service request and includes driving time to and from rig location. TIME DEFINITION Regular Time Rates opply between the hours of 7:00 ‘A.M. and 5:00 P.M. Monday through Friday except on holidays. Premium Time Rates apply between the hours of 5:00 P.M, fo 7:00 A.M. and all doy Saturday except hol days Holidays are Good Friday, Memorial Day, Indepe dence Bay. Labor Dey, Thanksgiving Day, end follow ing Friday, Christmas Eve Day, Christmas Day, and New Year's Day. SERVICE RATES Subject to time definitions, regular rates are: Service Rates Per Man Hour : $30.00 Premium Rate Per Man Hour 2-49.00 Holiday Rate Per Man Hour 50.00 Helper Rate Per Man Hour... 24.00 Service rates start when Skytop Brewster employee is assigned to the shop or field activity pursuant to the customer's service request. Prices subject to change without notice. All field service requests will carry @ minimum charge of 4 hours. ORDER CANCELLATION Orders which include items purchased by Skytop Brewster for the customer and/or items not in current Skytop Brewster production cannot be cancelled ‘except upon payment of an inventory handling charge. Orders which require Skytop Brewster engineering service cannot be cancelled except upon payment of an engineering charge. SKYTOP BREWSTER SERVICE CENTERS Victoria, Texas 20... .ceeeeee Odessa, Texas Lofoyette, Lovisiana Shreveport, Lovisiona Casper, Wyoming Edmonton Alberta, Canada Conroe, Texas 912-573-5590 915-563-3444 318.988.2560 318-222-7455 307-266-2517 403-465-9541 713-539-3101 EFFECTIVE DATE JUNE 1, 1981 PRICES SUBJECT TO CHANGE.PRIDE COLOMBIA a MUD PUMP - SKYTOP 1.300 T Eficiencia volumétrica 100% Eficiencia mecanica 90% Polea del “compund” 18” Polea de la bomba * 41,250" Relacion de poleas 2,29:1 Relacion de la bomba 447°1 Relacion total 10,2:1 RENDIMIENTO - RPM MOTOR |1000 J 800 | “Strokes” 120. | 100 80 oe wpe | 4.300 | 4.083 | 07 | Diametro GALONES POR MINUTO | de Camisa _ _ _ tid — 720. [600 | be - 620 | 517 er al 3 46 : TEORIA CON CAMISA DE 7” 1200 RPM motor [12 0-705 gal/min 10.2 Relacin total 10.2 6 Galones por “Stroke” Eficiencia mecanica 0.9 = 634 = gal/min