HHF-1600L Drilling Pump (Main Body) User Manual

HHF-1600L drilling pump（Main body）
NBC008-SC
June, 2018
I
Content
1. Safety warnings ............................................................................................................................1
2. Description of drilling pump......................................................................................... 1
2.1. Purposes and applicability ......................................................................................... 1
2.2. Standards for design and manufacture of drilling pump ............................................ 2
2.3. Brief working principle .............................................................................................. 2
3. Overall structure of drilling pump ................................................................................ 4
3.1. Overall structure of drilling pump ............................................................................. 4
3.2. Overall dimensions of HHF-1600 drilling pump ....................................................... 6
4. Structure description of main parts and components .................................................... 6
4.1. Power end .................................................................................................................. 6
4.2. Fluid end .................................................................................................................... 9
5. Lubrication .................................................................................................................. 12
5.1. Splash lubrication .................................................................................................... 12
5.2. Pressure Lubrication ................................................................................................ 13
6. Mud suction system .................................................................................................... 17
6.1. Suction pipeline ....................................................................................................... 17
6.2. Suction pulsation dampener ..................................................................................... 17
6.3. Suction filter ............................................................................................................ 18
6.4. Suction pipeline valve .............................................................................................. 18
7. Mud discharge system ................................................................................................ 18
7.1. Discharge six-way block .......................................................................................... 18
7.2. Safety valve.............................................................................................................. 18
7.3. Pressure relief pipeline............................................................................................. 18
8. Drilling pump device .................................................................................................. 18
8.1. Drilling pump device directly driven by diesel engine ............................................ 19
8.2. Drilling pump device driven by compound device .................................................. 19
8.3. Drilling pump device driven by motor .................................................................... 19
9. Installation of drilling pump ....................................................................................... 19
I
9.1. Installation foundation ............................................................................................. 19
9.2 Installation ................................................................................................................ 19
10. Use and maintenance of drilling pump ..................................................................... 22
10.1. Running of drilling pump ...................................................................................... 23
10.2. Maintenance of drilling pump................................................................................ 26
11. Possible troubles of drilling pump and troubleshooting ........................................... 36
11.1. Troubles and troubleshooting of fluid end ............................................................. 36
11.2. Troubles and troubleshooting of power end........................................................... 37
12. Repair of drilling pump............................................................................................. 38
12.4. Assembly of main components and parts for power end ....................................... 43
12.5. Replacement of discharge pulsation dampener...................................................... 49
13 HHF-1600 Drilling pump (single pump) factory matching range ............................. 51
14 Random tool（optional）....................................................................................... 51
15. Spare parts................................................................................................................. 52
16. Recommended one year spare parts list .................................................................... 53
II
Foreword
HHF-1600L drilling pump is one of the main supporting components for medium
and deep drilling rigs, and parts and components of the drilling pump are designed and
manufactured as per API spec 7K-2015 Specification for Drilling and Well Servicing
Equipment, the 6 edition, and relevant standards. It can satisfy the requirements of
drilling rig on drilling application.
This manual generally describes the technical specification, performance parameters,
transmission principle, overall structure, installation, use, maintenance, overhaul,
adjustment, troubleshooting, quick-wear part replacement and other precautions in use
for the drilling pump.
Operators must read this manual carefully before installation and operation. And
install, operate and repair the drilling pump as required. Improper installation, use or
repair may cause personal injury or equipment damage if the relevant contents are not
known.
The left and right of this pump are determined by looking from the power end to the
fluid end of the pump. This way is also used for determining the left, middle and right of
parts and components such as crosshead and hydraulic cylinder etc.
Each pump has an ex-factory serial number, and users shall point out the model and
the ex-factory serial number of the pump when ordering spare parts or inquiring relevant
things.
Components and parts list of HHF-1600L drilling pump refers to HHF-1600L
drilling pump parts list
There is a recommended spare parts list attached to this user manual as a reference
for users ordering spare parts. Detail parts list refers to parts list
※ Before the installation and use of the product, please read this user manual
carefully!
1
HHF-1600L drilling pump（Main body）user manual
Important safety statements

The personnel engaged in the use, management, operation, maintenance and repair
of product shall know related contents in the manual well, follow the normative
procedure about use, management, operation, maintenance and repair, and especially pay
attention to safety warnings and notices mentioned in this manual, national laws and
regulation, industrial regulations and general knowledge for avoiding human injury and
equipment damage.
It is not possible to list all contents of safety warnings in details in this manual.
Therefore, choose a proper way to operate the product for avoiding human injury and
equipment damage.
To maintain the product correctly is an important way to keep it in reliable and safe
running. The maintenance personnel shall maintain it as per the methods introduced in
this manual.
The correct repair of products and the replacement with components and parts from
original factories are import factors for the safe and reliable running of equipment, and
users must repair and replace the components and parts according to the
manufacturer-authorized right.
Please read the contents with following titles and marks carefully:
Warning: used in the conditions that may cause personal injury or death due to
inconformity with operation steps and methods;
Notice: used in the conditions that may cause equipment injury or damage due to
imprecise observation of operation steps and methods etc.
1. Safety warnings
 Only trained and qualified operators can install, operate and repair
equipment with qualification certificates.
 Prior to installation, operation and repair of drilling pump, operators shall
read this manual carefully, install, operate and repair the drilling pump as
per requirements.
 There shall be a chief principal designated for installation, operation and
repair, the persons participating in work shall be assigned with clear work,
and detailed and reliable safety measures shall be available.
 Do not run equipment in the dark unless there are proper lighting facilities.
 Persons on duty shall wear labor protection articles as required.
 The used hoisting and handling equipment must be matched with related
weight to be operated.
 In use process, strictly execute operation specifications and technical safety
rules.
 Make sure to release pressure inside pipelines to zero in the disconnection of
any high pressure pipelines or hoses. Follow similar procedures in wiring of
electric appliances and make sure to cut off power supply before trying
repair.
 It is forbidden to maintain and repair equipment when equipment runs.
 Do not overload equipment.
 Don't point high-pressure air at any positions of a human body, as it may
cause personal injury. It is forbidden to rotate ball bearing or roller bearing
with the high-pressure air. Do not point high-pressure air at fire.
2. Description of drilling pump
2.1. Purposes and applicability

HHF-1600L drilling pump is horizontal three-cylinder single-acting piston pump.
As important equipment for drilling application, it feeds circulating high-pressure
- - 1
drilling fluid to well bottom during work to flush the well bottom crush rocks, cool and
lubricate bits and carry rock debris to the surface.
Considering that the working medium of the drilling pump is mud, the minimal
temperature of the liquid mud is 0℃, and the minimal working temperature of the
drilling pump is 0℃.
Generally, working medium is water-base mud.In case of special requirements,
oil-base mud can be used, but the composition of oil-base mud should be provided to
the manufacturer for confirmation in advance, and parts should be replaced if
necessary.
2.2. Standards for design and manufacture of drilling pump

The parts and components of the drilling pump are designed in conformity with
API Spec 7K-2015 Specification for drilling and well servicing equipment, the 6th
edition.
2.3. Brief working principle

This drilling pump mainly comprises two parts: a power end and a fluid end. As
shown in Fig. 1, the power end consists of frame, pinion shaft, crank connecting rod
and cross sliding block mechanism, supplies power to the fluid end and converts
gyroscopic motion into straight reciprocating motion. Piston at fluid end performs
reciprocating motion in liner by means of the power from the power end, and jointly
acts together with suction valve and discharge valve to compress low-pressure mud
and discharge high pressure mud.
- - 2
1. Frame assembly 2. Crankshaft assembly 3. Pinion shaft assembly 4. Crosshead

assembly 5. Fluid end assembly
Fig.1: drive schematic diagram of drilling pump
2.4. Technical parameters of drilling pump table 1
No. Model HHF-1600L
1 Type horizontal triplex single-acting piston pump
2 Rated input power 1600hp（1193kW）
3 Max. liner diameter 7 1/4″（184.15mm）
4 Stroke length 12″（304.8mm）

5 Rated stroke rate 120 SPM
6 Gear type Herringbone tooth
7 Gear drive ratio 4.206:1
8 Max. displacement 772GPM
9 Maximum pressure 5000psi
10 Size of valve chamber API 7#
11 Weight of main body 25150kg
- - 3
2.5. Performance parameters of drilling pump table 2
Liner diameter and rated pressure
Stroke 7 1/4″ 7″ 6-3/4″ 6-1/2″ 6 1/4″ 6″ 5-1/2″ 5″
184mm 178mm 171mm 165mm 159mm 152mm 140mm 127mm
rate HHF-1600L 3197 22 3690 25.4 3978 27.4 4303 29.7 4668 32.2 5000 34.5 5000 34.5
3430 23.6
SPM psi MPa psi MPa psi MPa psi MPa psi MPa psi MPa psi MPa psi MPa
Rated power Displacement
130 1733 hp 836 GPM 780 GPM 725 GPM 672 GPM 621 GPM 573 GPM 481 GPM 398 GPM
1292 kW 52.76 L/s 49.21 L/s 45.74 L/s 42.40 L/s 39.21 L/s 36.15 L/s 30.35 L/s 25.11 L/s
120 * 1600 hp* 772 GPM 720 GPM 669 GPM 621 GPM 573 GPM 529 GPM 444 GPM 367 GPM
1193 kW* 48.7 L/s 45.42 L/s 42.21 L/s 39.18 L/s 36.19 L/s 33.37 L/s 28.01 L/s 23.15 L/s
1 6.43GPM 6.00 GPM 5.58 GPM 5.17 GPM 4.78 GPM 4.41 GPM 3.70 GPM 3.06 GPM
0.4058L/s 0.3785L/s 0.3520 L/s 0.3262 L/s 0.3016L/s 0.2782L/s 0.2334 L/s 0.1931L/s
Note: 1. Calculate as per volumetric efficiency (100%) and mechanical efficiency

(90%).
2. Sign * shows the rated stroke number during operation and rated input power
corresponding to rated stroke number.
3. Overall structure of drilling pump
3.1. Overall structure of drilling pump

As shown in Fig. 2, it mainly comprises two parts: the power end and the fluid
end. The power end comprises: frame assembly, drive shaft assembly, crankshaft
assembly and crosshead assembly etc, and the fluid end comprises hydraulic cylinder,
valve assembly, liner, piston assembly, suction pipe, discharge pipe, discharge
pulsation dampener, safety valve and spray device etc.
The drilling pump is equipped with small crane and one set of special tools for
daily maintenance.
- - 4
1. Frame assembly; 2. Crankshaft assembly; 3. Pinion shaft assembly; 4. Crosshead

assembly; 5. Small crane; 6. Fluid end assembly
Fig.2 overall structure drawing of drilling pump
- - 5
3.2. Overall dimensions of HHF-1600L drilling pump

As shown in Fig. 3.
Fig. 3: overall dimensions drawing of drilling pump
4. Structure description of main parts and components
4.1. Power end

The power end comprises frame assembly, pinion shaft assembly, crankshaft
- - 6
assembly and crosshead assembly etc.
4.1.1. Frame assembly
The frame assembly comprises frame, back cover and small crane etc.
The frame is welded into box body structure by steel plates and formed into frame
parts by rough machining and finish machining after stress relief treatment. The frame
is the basic part of drilling pump, and all parts and components of drilling pump are
installed on the frame. Oil sump and lubrication oil way are arranged in the frame to
supply lubrication for gear, bearing and crosshead etc. The small crane with lifting
capacity of 500kg is installed on the frame for lifting liner.
4.1.2. Pinion shaft assembly
Fluid
end
1. Key; 2. Pinion shaft; 3. Wear sleeve; 4. End cover; 5. Sealing washer; 6. Sealing
washer;
7. Bearing sleeve;8. Retainer ring; 9. Sealing washer; 10. Oil collector; 11. Bolt; 12.
Bolt; 13. Oil seal;
14. Bearing; 15. Washer 22; 16. Washer; 17. Flange; 18. Bolt; 19. Washer 16
Fig.4 pinion shaft assembly
The pinion and shaft have an integral structure as shown in Fig. 4. The pinion is
herringbone gear with tool withdrawal groove. Support bearing is rib-free radial
cylindrical roller bearing and is convenient for overhaul, assembly and disassembly.
The extensions of two ends of the shaft ends are the same, and power can be input
from any end or both ends in the same way.
- - 7
4.1.3. Crankshaft assembly
The crankshaft assembly comprises crankshaft, big gear ring, connecting rod,
crankshaft bearing and connecting rod bearing etc. The crankshaft assembly is installed
on the frame by self-aligning roller bearing. (Refer to Fig. 5.)
Fluid
end
1. Main bearing end cover; 2. Main bearing sleeve; 3. Sealing washer; 4. Inner
retainer ring ;5. Outer retainer ring; 6. Connecting rod; 7. Locating ring (I); 8.
Crankshaft; 9. Locating ring (II) 10. Big gear ring; 11. Bolt 12. Distance ring; 13. Main
bearing sleeve; 14. Retainer ring; 15. Baffle plate
16. Bolt, main bearing; 17. Gasket unit; 18. Screw; 19. Stop nut; 20. Bolt; 21. Bolt;
22. Connecting rod bearing;
23. Main bearing; 24. Washer; 25. Locking steel wire; 26. Locking steel wire; 27.
Screw
Fig. 5: crankshaft assembly
- - 8
Crankshaft is an integral cast eccentric shaft. Three toggles are subjected to

trisection as per 120°.
The integrally machined gear ring of herringbone tooth is installed on the
crankshaft.
Three connecting rod big-head bearings are single-row short cylindrical roller
bearings and are installed respectively on three eccentric toggles of the crankshaft.
Connecting rod small head is installed on crosshead pin through double-row long
cylindrical roller bearing.
4.1.4. Crosshead assembly
Crosshead assembly comprises crosshead, guide plate, crosshead pin and
intermediate tie rod (intermediate rod) etc. Upper and lower guide plates are installed
on frame and form guide plate hole; through crosshead pin, crosshead is driven by
connecting rod to perform reciprocating motion in guide plate hole; and intermediate
tie rod installed on crosshead is connected to piston rod and drive piston to perform
reciprocating motion.
4.2. Fluid end

Fluid end mainly comprises hydraulic cylinder, liner, piston, valve, suction pipe,
discharging pipe, discharge pulsation dampener, safety valve and spray device etc. The
main structure refers to Fig. 6.
- - 9
1. Seal ring of cylinder liner 2. Wearable disc 3. Liner flange 4. Liner gland 5. Liner 6.
Locking ring 7. Piston rod 8. Clamp assembly 9. Spray device 10. Seal ring of piston
11. Pison 12. Locknut 13. Valve cap sealing ring 14. Valve cap 15. Valve gland 16.
Discharge hydraulic cylinder assembly 17. Seal ring of discharge pipe 18. Discharge
pipe 19. Suction hydraulic cylinder 20. Valve rod guider 21. Spring guide 22. Valve
spring 23. Valve assembly 24. Suction pipe
Fig.6 fluid end assembly
4.2.1. Hydraulic cylinder
Hydraulic cylinder comprises suction hydraulic cylinder and discharge hydraulic
cylinder, it has L-type structures, and structure and size of valve chamber accord with
API 7K specification. The hydraulic cylinders are connected and fixed to frame by
bolts.
- - 10
4.2.2. Liner
The drilling pump adopts bi-metal liner. Liners with different diameters can be
selected as per different drilling conditions. Liner is fixed and connected on hydraulic
cylinder with bolt through liner flange and liner gland. Liner together with piston and
piston rod can be put in or taken out from the opening above the frame with the help of
small crane arranged on pump.
4.2.3. Piston
The piston consists of piston core, piston rubber sheet, clamp plate and circlip.
Piston rod is connected to intermediate tie rod through hoop, and then piston and
piston rod are connected into a whole by piston nuts.
4.2.4. Liner spray device
Liner spray device consists of spray pump, water tank and spray manifold etc. It is
used for rinsing, lubricating and cooling liner and piston in the running process of
pump, so as to prolong the service life of liner and piston. The installation position of
the spray pipe is as shown in Fig. 7.
2
1
3
1. Fixing frame; 2. Connecting pipe; 3. Spray pipe

Fig. 7: liner spray pipe
4.2.5. Valve
The valve comprises valve body, valve seat, valve spring and valve rod guider etc.
Suction valve and discharge valve are fixed by valve cover.
4.2.6. Suction pipe
Suction pipe is connected to 3 hydraulic cylinders simultaneously. It has left,
- - 11
middle and right suction port, and drilling fluid can be sucked from the left, right and
middle of the pump.
4.2.7. Discharge pipe
Discharge pipe is connected to 3 hydraulic cylinders simultaneously. It has left
and right interfaces, and drilling fluid can be discharged from left or right of the pump.
4.2.8. Discharge pulsation dampener
Discharge pulsation dampener mainly comprises shell, cover, air bag, air releasing
valve and pressure gauge etc. The discharge pulsation dampener is installed on six-way
block (or four-way block or five-way block) of discharge pipeline, and pressure
fluctuation of the drilling fluid can be reduced when it is used properly.
4.2.9. Safety valve
Drilling pump adopts shear pin safety valve (or spring safety valve), and is
installed at six-way block (or four-way block or five-way block) of discharge pipeline.
By correctly using the safety valve, the drilling pump can be prevented from pressure
built-up, to ensure the safe running of the drilling pump.
4.2.10. Spray device
The spray device consists of spray pump, water tank and spray pipe etc. The spray
pump is installed on the side surface of the pump, water tank is installed below frame,
and spray pipe is fixed on frame above liner. Spray device directly sprays cooling
water onto liner and piston to play rinsing, lubrication and cooling roles.
5. Lubrication
Gear, bearing, crosshead sliding way and bearing of power end all adopt oil
lubrication way of combining splash lubrication and forced lubrication. In addition, the
forced lubrication includes internal way and external way. Liner and piston at fluid end
are lubricated, washed and cooled with the water supplied by spray pump.
5.1. Splash lubrication

The splash lubrication system of drilling pump has nothing to do with pressure
lubrication system. In the splash lubrication system, the big gear ring brings the oil up
from the sump, and when the bull gear is engaged with the pinion, the oil is squeezed
- - 12
out and splashed to various oil grooves of the frame. The pinion shaft bearing, the
crosshead bearing and the guide plate are lubricated. (Refer to Fig. 8.)
The lubrication oil way of the crosshead bearing is as shown in Fig. 8. The
lubricating oil is accumulated in oil chamber at the upper part of crossheads, flows
through oil nozzle into the crosshead pin baffle plate, and then enters oil passages to
lubricate crosshead bearing.
1
2
4
3
5
1. Oil nozzle; 2. Crosshead pin baffle plate; 3. Bolt; 4. Crosshead pin; 5. Oil way
Fig. 8: lubrication oil way of crosshead bearing
5.2. Pressure Lubrication

The pressure lubrication system of the drilling pump is shown in Fig.9: in this
system, through joint seat II, oil pump sends oil to pinion shaft nozzle, main bearing oil
pipe and crosshead chamber joint seat I, and then through joint seat I, distributes oil to
crosshead, crosshead bearing and intermediate tie rod.
- - 13
4
1 3A
2
8
6
9 3 3A
8 7 4A
5 4
2
9
1. Suction oil filter; 2. Joint seat II; 3. Oil pipe; 3A. pinion shaft nozzle; 4. Main
bearing oil pipe
4 A. crosshead chamber joint seat I; 5. Pressure gauge; 6. Safety valve; 7. Oil groove; 8.
Oil pipe; 9. Oil pump
Fig. 9: pressure lubrication system of drilling pump
Lubricating oil pump of drilling pump has two installation modes of “internal
way” and “external way” selected by user. If the user does not request specially, the
“internal way” is adopted usually. No matter which way is adopted, both pressure
lubrication pipe systems are the same.
5.2.1. “Internal way” oil pump pressure lubrication
- - 14
As shown in Fig. 10, oil pump is installed in the chamber of frame, and the drive
gear of the oil pump is driven by the big gear ring of the oil pump, the side of the drive
gear of the oil pump is required to be aligned with the side of the big gear ring of the
drilling pump, and the gear backlash is 0.0236″-0.0354″ (0.60-0.90mm).
2 1
1. Pinion; 2. Big gear ring; 3. Oil pump drive gear

Fig.10: installation sketch of "internal way" oil pump
For ensuring the normal operation of lubricating oil pump, the rotation direction of
oil pump is as shown in Fig. 10. For ensuring the lowest oil-supplying pressure of
lubrication oil pump to be 5 Psi (0.035MPa), the lowest stroke rate of drilling pump's
operation shall not be less than 25s/min.
5.2.2. Pressure lubrication of mechanically-driven oil pump
3 2 1
- - 15
1. Gear oil pump; 2. Drive belt; 3. Guard
Fig. 11: pressure lubrication of mechanically-driven oil pump
As showed in Fig.11, the pinion shaft of drilling pump drives gear oil pump to run
by V-type belt transmission and supplies pressure lubrication oil to drilling pump.
5.2.3. Electric oil pump pressure lubrication
Pump skid
Oil diverter
Drill pump
Centerline
of bent axle
Pump skid
1. Utilized motor gear pump; 2. Electric pressure switch; 3. Overflow valve; 4. Oil
pressure gauge;
- - 16
5. Oil suction filter; 6. Magnetic filter
Fig. 12: pressure lubrication drawing of electric oil pump
As showed in Fig. 12, motor drives the gear oil pump run and supplies pressure
lubrication oil to drilling pump.
Notice: before the start of drilling pump, the electric lubrication oil pump must
be started firstly to adequately lubricate all mechanical rotating components prior to
work.
5.2.4. Lubrication oil
AGMA industrial extreme pressure gear oil. The brands are as follows:
Ambient temperature +30℉ to +155℉ (-1℃ to +68℃)
AGMA 250.04EP (6EP) or ASTM/ISO VG320
Ambient temperature 0°F～+80°F （-18°C～+27°C)
AGMA 250.04EP(5EP) or ASTM/ISO VG220
Ambient temperature -20℉ to +40℉ (-29℃ to +4℃)
AGMA 250.04EP (4EP) or ASTM/ISO VG150
Volume of oil sump: HHF-1600 pump: 130US gal(492L)
6. Mud suction system
6.1. Suction pipeline

Drilling pump can perform natural suction as well as charge suction. The pipeline
adopting natural suction is short as much as possible and better has no elbow, and the
size of the pipeline is at least the same with that of the suction inlet of pump (if the
pipeline is longer than 6 feet, the size shall be increased).
The pipeline adopting charge suction can be bent as required. The charge pump shall
have bypass pipeline connection, and when the charge pump goes wrong or is repaired,
the drilling pump can still work continuously as per natural suction way.
6.2. Suction pulsation dampener

Welded type suction pulsation dampener must be installed in front of all valves in
suction pipe, and flange type suction pulsation dampener must be connected with the
inlet flange of the suction pipe of pump directly.
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6.3. Suction filter

The pipeline adopting natural suction shall be provided with suction filter. The
suction filter shall be arranged in the front of charge pump adopting charge suction.
6.4. Suction pipeline valve

The suction pipeline valve must be safety valve or gate valve or butterfly valve. It
cannot be resistance valves such as plug valve.
7. Mud discharge system
7.1. Discharge six-way block

The discharge six-way block (or four-way block or five-way) is connected with
discharge pipe, the discharge pulsation dampener is installed at the top of the discharge
six-way block (or four-way block or five-way), and pressure gauge and safety valve
are respectively installed on two sides of the discharge five-way block (or four-way
block).
7.2. Safety valve

The safety valve must be installed in the front of shut-off valve, thereby
preventing pump from being damaged due to accident startup of pump when the valve
is closed, and the pressure release pipe of safety valve can be only led into the mud
suction tank and cannot be connected with mud suction pipeline.
The pressure of the safety valve is set not to be 10% higher than the max. rated
pressure corresponding to a liner being used.
7.3. Pressure relief pipeline

A bypass pipe with a valve is installed between a discharge pipeline connected
with safety valve and the pressure relief pipeline of the safety valve, so as to release
mud pressure when the discharge manifold needs detached or repaired.
8. Drilling pump device

The drilling pump device comprises drilling pump, driving and drive devices,
mud charge system, pressure relief manifold and big skid of pump device etc.
- - 18
8.1. Drilling pump device directly driven by diesel engine

The drilling pump device directly driven by diesel engine mainly comprises
drilling pump, diesel engine, cardan shaft and V belt drive device etc. The diesel
engine can be used for directly driving the V belt drive device and the drilling pump.
The mud charge system is installed separately, and the high pressure mud blowdown
manifold is connected with blowdown interface of safety valve and is led into mud
suction tank.
8.2. Drilling pump device driven by compound device

Compound device drives drilling pump by air tube clutch and cardan shaft. The
mud charge system is installed separately, and the high pressure mud blowdown
manifold is connected with blowdown interface of safety valve and is led into mud
suction tank.
8.3. Drilling pump device driven by motor

Motor directly drives V belt or chain drive device and drives drilling pump. The
mud charge system and pump are uniformly installed on the skid of drilling pump
device, and the high pressure mud blowdown manifold is connected with blowdown
interface of safety valve and is led into mud suction tank.
9. Installation of drilling pump
9.1. Installation foundation

The foundation for bearing pump must be in contact with pump uniformly along
the full length of the pump. The fixing bolts shall be screwed up uniformly to prevent
causing additional stress of pump skid.
9.2 Installation
In order to ensure the reasonable distribution of lubricating oil at power end when
pump runs, the pump placed on the foundation must be horizontal.
9.2.1 Ground installation
- - 19
In ground installation, as shown in Fig.12, at least eight 4''×12'' (102mm×305mm)
spacers are used and padded in the length direction of pump skid at the positions as
shown in Fig.13. The foundation below the base plates must be above 12'' (305mm)
wider than the skid of pump.
Fig.13: ground installation schematic diagram of base plates
9.2.2. Fixation and installation

Install pump on the structural member bases on drill ship or drill floor.
As showed in Fig. 13 and Fig. 14, when pump skid are fixed and installed by bolts,
pad the skid with spacers to prevent power end frame from generating possible torsion
or inclination. Notice: before bolts are screwed up, the pump skid must be padded
compactly to prevent generating additional stress to pump skid while screwing up bolts.
The width of the spacers is required to be not less than that of the wing plate of the
skid beam and its length cannot be less than 12'' (305mm).
When power device or motor and pump skid are installed integrally, the pump set
is mounted on a T-type beam skid and provided with stop block without being fixed by
using bolts. The pump can float, thereby preventing the deformation of pump frame
due to the deformation of ship or platform.
- - 20
3 4
1. Pump skid 2. Spacer 3. T-type steel 4. Plate

Fig.14: ship base plate installation schematic diagram
9.2.3. Installation of drive device
The installation and alignment etc of drive device between pump and power
source refer to related chapters of User Manual of Utilized Pump in detail, and the
following contents are for reference only.
9.2.3.1. V belt drive
(1) Belt tension
Apply force Wd perpendicular to belt in the middle of two points of
tangency between belt and belt wheel so that the belt generates deflection f:
Newly installed belts: Wd= 600N f≈27mm
Used belts: Wd= 600N f≈32mm
(2) Check centration of belt wheel
After V belt is installed and tensioned, check belt wheel for centration. The end
faces of two belt wheels are coplanar and allowable error cannot be more than 1mm.
9.2.3.2. Chain drive
(1) Check centration of sprocket wheel
Check the centration of chain wheel after installation. The end faces of two belt
wheels are coplanar and allowable error cannot be more than 1mm, after the chain
wheels are installed in conformity with requirements, install chain.
(2) Lubrication of drive chain
- - 21
As an independent system, in chain drive device of drilling pump, chain
lubrication system has an independent lubrication oil pump, oil tank (namely chain box)
and lubrication oil pipeline. The brands of the lubrication oil are as follows:
Ambient temperature above -40℃ ISO VG 220 synthetic gear oil
Ambient temperature -10℃ to +40℃ ISO VG 220 industrial gear oil
9.2.4. Installation of mud suction system
The natural suction system and the charge suction system are respectively
installed as required.
9.2.5. Installation of mud discharge system
The mud discharge system is installed as required.
9.2.6. Installation of drilling pump device
The drilling pump device (utilized drilling pump) comprises drilling pump, power
drive device, mud suction system and mud discharging system, which are installed on
the same skid and transported as a module. The drilling pump device has been installed
and commissioned as per design requirements in factory. User only needs to install
according to the requirements of drilling well site layout.
10. Use and maintenance of drilling pump

Safety warning: For any stored pump, no matter being used at well site or
transported from factory, it is required to be checked before putting into operation.
Make sure every part of pump is available and good.
Safety warning: When any of mechanical and electric parts of drilling pump is
running, all safety devices shall be in normal and effective status, including: air-off
protection of AC VF motor cooling blower, pressure alarm of lubrication system, the
power-off protection of mud charge system motor, matching between the limiting
pressure of mud pump discharging safety valve and liner diameter, the consistency of
inflation pressure of discharge pulsation dampener pressure and the related
requirements etc. These safety devices should be checked and confirmed to be
effective by every shift.
Safety warning: power source must be cut off for repair and maintenance.
- - 22
Visible warning plates shall be hung.
Safety warning: when you repair the mud discharging pipeline, the bypass
valve of discharging pipeline must be opened first and high pressure of mud has to
be released to be zero.
10.1. Running of drilling pump

10.1.1. Preparation before running
10.1.1.1. Check whether every part of drilling pump device and pump is connected,
installed and tightened according to related requirements. Check whether any foreign
matter exists in pump body or main frame.
10.1.1.2. Open top view hole cap of pump, add enough lubrication oil into pinion
bearing oil groove and crosshead oil groove to ensure full lubrication of all friction
surfaces of pump before operation.
10.1.1.3. Fill power end lubrication oil as per lubrication requirements. (Notice: oil
level shall be measured when pump stops.)
10.1.1.4. Check whether all valves on mud pipelines are at “on” or “off” positions
before starting.
10.1.1.5. Check whether the air charging pressure of discharge pulsation dampener
reaches the regulated value ≤4.5MPa (650psi).
If the discharge pulsation dampener has a separate operation manual, please follow its
rules.
Note: only nitrogen can be filled into discharge pulsation dampener, and oxygen,
compressed air or hydrogen is not allowed. Air pressure in pulsation dampener
shall not exceed 0.2MPa during transportation and storage.
10.1.1.6. Check whether relief valves and pressure gauges are complete and sensitive,
and whether safety valves are set correctly.
10.1.2. Requirements before starting drilling pump
10.1.2.1. It must start electric lubrication oil pump before starting drilling pump. Make
sure that gears and crosshead of power end are fully lubricated before starting drilling
pump.
- - 23
10.1.2.2. Spraying pump may be started at the same time with drilling pump, or started
before the drilling pump. However, the drilling pump cannot be started before the
spraying pump started any time. Notice: if the cooling agent is water-base liquid, it is
recommended to add antiseptic (such as emulsified oil or motor oil) for protecting the
parts from corrosion.
10.1.2.3. Charge pump may be started at the same time with drilling pump, or started
before the drilling pump.
10.1.2.4. Before drilling pump starts with pressure, be sure to fill the cylinders and
discharging pipelines of fluid end fully. Because air inside pump cannot be cleared out
completely under conditions of pressure, so it will seriously affect the stability of pump
running and service life of pistons and valves. The way to fill the pump fully: open
pressure relief pipeline or mud gun pipeline, start pump to run until the air inside is
released completely.
10.1.2.5. Water baffle must be installed on intermediate tie rod before starting drilling
pump.
10.1.2.6. Liner end cap must be installed before starting drilling pump.
10.1.3. Start of drilling pump
10.1.3.1. Start at slow speed: starting speed shall be as low as possible, then speed up
step by step. Ensure that fluid flowing speed inside suction pipeline can meet the
requirement of pump suction speed without any gas etching.
10.1.3.2. Natural suction operation: when pump is running under natural suction
condition, pump speed is limited by the filling degree of pump. If some mental
knocking sound can be heard from the fluid end of pump while running, it means that
pump has been gas-etched and not fully filled. At this moment, charging pump shall be
started until knocking sound disappears and operation turns to normal, then natural
suction shall be adopted again.
10.1.3.3. Charging suction running: before starting charging pump, if diaphragm
pulsation dampener is used, tire air charger pump shall be used to charge air for suction
pulsation dampener. Air charging pressure is 0.1MPa (15 ponds /inch2). Diaphragm
- - 24
fluctuation range shall be at observation window bottom or middle point.
Safety warning: it will lead to equipment damages and personal injuries if high
pressure air supply or nitrogen is used for charging the suction pulsation dampener.
10.1.3.4. The pressure of mud discharging pressure gauge shall be watched very
carefully at pump starting. Before mud returns to ground, operator is not allowed to
leave.
10.1.3.5. When pump is lubricated by internal type or mechanical drive way pressure
lubrication, for ensuring full lubrication of power end, pump speed cannot be too low,
i.e. pump stroke speed cannot be lower than 25s/min.
10.1.3.6. Check the pressure of lubrication system of power end for conformity with
regulations: 0.035-0.103MPa (5-15psi).
Check the oil level for conformity with requirements. After start, if oil level is below
the lowest limit, it needs to fill more oil.
10.1.3.7. It is forbidden to water the intermediate tie rod and stuffing box end cover.
10.1.4. Monitor in drilling pump running
Safety warning 1: when it needs to perform maintenance or replace parts in the
running, it must stop operation and cut off power source.
Safety warning 2: When high pressure mud system needs maintained, it must
open bypass valve of discharging pipelines and release high pressure to
zero, then dismantle and repair.
Safety warning 3: the highest discharging pressure of drilling pump cannot
exceed the limit of "liner diameter and rated pressure". Safety valve
shall be set according to related rules.
10.1.4.1. Check connection clamp between piston rod and intermediate tie rod for
abnormal sound. Tighten clamp bolts or replace with qualified clamp, piston rod or
intermediate tie rod if any abnormal sound exists.
10.1.4.2. Check all bolts, nuts and valve caps on hydraulic cylinders for looseness.
Tighten them as required in time if looseness exists.
10.1.4.3. Check alarm hole at high-pressure sealing position for overflow drain. Check
- - 25
any damage or leaks at valves and liners of pump. Replace damaged parts in time if
such condition exists.
10.1.4.4. Check bearings, crossheads guide plates and other relatively moving parts for
normal temperature and temperature rise, and treat in time if any abnormality exists. .
10.1.4.5. Observe lubrication oil system pressure, the water supply of spray pump, the
variation of pump discharging pressure, if any abnormality exists, treat it in time
10.2. Maintenance of drilling pump

10.2.1. Daily maintenance
(1) Check the oil level of the power end after the pump is stopped. Do it once
everyday. Check the oil level of chain drive box if chain drive is adopted. Check if the
pressure gauge of lubrication system is displaying properly at work.
(2) Observe the working conditions of the liner and piston. The leakage of a little
mud is normal. If the leakage is serious, it needs to check the abrasion of piston and
liner inner hole, and if the abrasion is serious, the liner and piston shall be replaced.
Notice: when replacing liner, liner sealing ring must be also replaced at the
same time.
(3) Check the liner cavity of frame, if lots of mud deposits, clean it.
(4) Inspect whether there is sufficient water in water tank for spray pump or not,
whether the cooling water is polluted or not, change water after cleaning water tank in
time if necessary.
(5) Check the air charging pressure of the discharge pulsation dampener for
conformity with requirements of operation conditions.
(6) Periodically check the shear pin (spring) safety valve for reliability.
(7) Loosen the piston rod hoop every day, rotate piston about 1/4 circle and then
fasten the hoop. This ensures that the pistons wear evenly and extend the service life of
piston and liner.
(8) Check cylinder head and valve cap for looseness once per 4h.
(9) Observe valve cap sealing, liner seal and relief hole of liner seal, if mud is seen
to flow out, replace corresponding seal ring timely.
- - 26
10.2.2. Weekly maintenance
(1) Dismantle the valve cover and cylinder head once a week, and clean them
thoroughly. Check the inner bushing of valve rod guider for abrasion, replace it with
new one if it is worn seriously and the clearance between valve guide rod and inner
bushing excesses 0.11" (3mm). Coat thread with molybdenum disulphide compound
calcium base grease when reinstalling valve cover and cylinder head.
(2) Check the condition of valve and valve seat, replace them if valve rubber, valve
body and valve seat are badly worn or washout (note: valve seat, valve body should be
replaced together).
(3) Check piston locknut and replace with new locknut if it is corroded or damaged.
(Notice: after nut is disassembled for three times, the sealing ring embedded inside has
no locking capacity.)
(4) Drain water from the pipe plug at drainage hole cover of frame until oil appears.
10.2.3. Monthly maintenance
(1) Dismantle and wash discharge filter.
(2) Check all stud bolts and nuts of fluid end. Such as connecting bolts and nuts for
suction hydraulic cylinder and discharge hydraulic cylinder, bolts and nuts for
connecting liner flange, hydraulic cylinder and frame, and connecting bolts and nuts
for suction pipeline and discharge pipeline, etc. If they are loose, tighten them as per
specified torque.
(3) Check the sealing ring in packing box for intermediate tie rod, which shall be
replaced with new sealing ring if being worn to leak. Replace them once every 3
months generally. Pay attention to oil seal azimuth during replacement (referring to Fig.
15).
- - 27
Connecting
rod
1. Crosshead; 2. Intermediate tie rod; 3. Two-lip seal; 4. O-ring; 5. CCK

type oil seal
Fig. 15: assembly drawing of oil seal
(4) Check and tighten the screws for lubrication system oil groove, and gear
scrapper plate should be in correct position.
(5) Every 6 months or when confirming the oil is polluted severely, replace all lube
oil in crosshead sediment cavity and power end oil sump with new oil after cleaning
the oil grooves by magnets.
10.2.4. Yearly maintenance
(1) Inspect the crosshead guide plate for tightness, add shims under guide plate to
adjust the clearance between crosshead and guide plates to meet the specified
clearances.
(2) The crosshead should be rotated 180° firstly and then it can be used when
replace the guide plate or dismantle the crankshaft assembly.
(3) It is recommended to check the whole pump thoroughly once per two or three
years. Check main bearings of crank shaft, pinion shaft bearing, connecting rod
bearings, crosshead bearings for wear and damage, replace if necessary.
(4) Inspect gear surface for abrasion and wear, if badly, the crankshaft and pinion
- - 28
shaft should be reinstalled by changing their direction simultaneously to use the
unworn gear surfaces.
(5) Replace seal of rear cover, crankshaft end covers etc, and replace all seals if
necessary.
(6) Check the tightness of all foundation bolts of pump skid. Retighten them as per
the requirements if necessary.
10.2.5 Mud pump overhaul
10.2.5.1 Test items：
It is recommended to check the whole pump thoroughly once per two or three years.
Mainly check the following contents:
The drilling pump overhaul main contents table 3
No. Check Drawing No. Check contents Acceptance standards: Remark
items
(1). bearing
(1.1) Main NB100.02.22 Whether the The bearing member has
bearing bearing member damage or clearance ＞
3G3003760HY
is damaged or 0.4mm that must be scraped
(1.2) Eccentric NB100.02.21 cracked, the The bearing member has
wheel flange or the damage or clearance ＞
bearing rolling surface
929/660.4QU 0.5mm that must be scraped
has pitting,
(1.3) Pinion shaft NB100.03.12 The bearing member has
bearing flaking and
damage or clearance ＞
4G32844H overproof
clearance. 0.45mm that must be
scraped
(1.4) Crosshead NB100.04.17 The bearing member has
bearing damage or clearance ＞
254941QU 0.3mm that must be scraped
(2). Main parts and components
(2.1) Big gear NB100.02.10 Gear crack, 1. Gear crack, broken teeth, When
ring broken teeth, pitting corrosion of the teeth replacing
(2.2) Pinion NB100.03.02 pitting surface ＞2mm must be the big
corrosion, wear scrapped gear, the
and pinion
agglutination 2. Damaged or deformation must
deformation ＞1mm or existing shallow engage
pitting corrosion , gear and with the
pinion can be recovered as unused
mesh requirement if already tooth
adjustment then must be surface
scrapped
(2.3) Pinion NB100.03.02 Crack, concentri 1. Thread or work shaft
- - 29
shaft city, match parts segment and bearing shaft
wear neck coaxial ＞0.3mm must
be scrapped
2.Repair of the wear parts
out of tolerance should be
follow brush plating, spray
welding, GMAW
(2.4) Crankshaft NB100.02.08.00 The shaft neck, 1.Crack must be scrapped

rounded corners, 2. Repair of the wear parts
match parts out of tolerance should be
wear degree follow brush plating, spray
welding, GMAW
(2.5) Connecting NB100.02.06 Crack, 1.Any crack and

rod straightness, straightness error＞0.5mm
small head hole must be scrapped
size
2.Small head hole out of
tolerance or out-of-round
then repair
(2.6) Crosshead NB100.04.01 Work surface 1. Scrap if crack or wear >

wear, taper hole 2mm or deep > 3mm more
size, connecting than 5 points, taper hole
thread and tie overproof or pull rod thread
positioning hole damage
of pull rod, 2. Pull rod positioning hole
compression overproof should be
screw thread repaired, redrill the thread if
compression screw hole
damage
(2.7) Upper NB100.04.02 Guide plate Scrap if crack or wear >
guide plate surface 2mm or deep > 3mm more
(2.8) Lower NB100.04.15 than 5 points
guide plate
(2.9) Fluid end HTNB164.00 Connecting 1. It shall be scrapped if
assembly threads, fatigue crack is existed in
connecting sizes inner chamber or damaged
position is hard to repair;
2. It shall be scrapped if
screw thread is damaged
exceeding 1/8 circles or
abrasion＞1/8 of screw
pitch when perform quick
disassembly or assembly;
3. It can be repaired to use if
- - 30
conical surface of valve seat
and other sealing positions
failed.
4. Connecting holes shall be
repaired if loose or
damaged.
(2.10) Air bag Full surface, 1. Scrap if there is crack
cover seal, threaded 2. Seal abrasion can be
connecting hole repaired, but manual
welding is not allowed
3. The threaded hole loose
or damage can be repaired
(2.11) Discharge Full surface, 1. Scrap if there is crack
pipe, seal, threaded 2. Seal abrasion can be
elbow or connecting hole repaired, but manual
five way welding is not allowed
3. The threaded hole loose
or damage can be repaired
(3)、 Fastener Check the Retighten the bolts as
tightness of the required
connecting bolts
(4)、 Repairable parts
(4.1) Valve HTNB164.04
cover
(4.2) Valve HTNB164.02.00
cover plug
(5)、Should be replaced parts
(5.1) Rubber
seal parts
(5.2) Sealing
rings
(5.3) Charging
connector,
grease
nipple,
Spray
nozzle
(5.4) Liner
(5.5) Piston
assembly
(5.6) Valve
assembly
(5.7) Pump and 1-8×3 1/2
base
connecting
bolts and
nuts
(5.8) Air bag HTNB021.04.03
connecting
- - 31
bolts and HTNB021.04.04
nuts
(5.9) Safety
componen
ts (such as
relief
valve,
control
valve
block,
etc.)
(5.10) Filter
element of
pipeline
filter
(5.11) Valve NB100.05.10
spring
(5.12) Wearable NB100.05.15.00 Check for stab Scrap if there is stab
disc wounds and wounds and wear
(5.13) Packing NB100.04.05 wear
box
(5.14) Piston rod NB100.05.18
(5.15) Clamp NB100.05.22.00
assembly
(5.16) Intermedia NB100.04.12
te tie rod
(5.17) Valve seat NB100.05.11.06
(5.18) Bearing
block
(5.19) Key
(5.20) Fastener
Note: in the above table, the parts replacement according to the specific extent of
damage.
10.2.5.2 assembly technical requirements
Above parts in the test and replacement should be in accordance with the relevant
inspection and assembly standards and drawings requirements, prevent cause
secondary damage to the parts.
(1) the parts must be cleaned before inspection, assembly after inspection qualified.
(2) the repaired hydraulic cylinder, discharge line, discharge air bag and so on main
load bearing parts or drawings required test for pressure shall be carried out in
accordance with the original drawings requirements.
(3) the process and inspection of parts assembly and equipments assembly according to
- - 32
the original product technical requirements.
(4) the requirements of main bolt tightening torque refer to table 1.
(5) the main parts and components refer to table 3 or the original design requirements.
(6) safety components such as relief valve should be matched liner pressure rated
value.
10.2.5.3 Test methods and requirements
The replaced parts should follow the standard or drawing requirements to take pressure
test and gas tightness test, etc.
After repair shall be according to the standard or test outline carried out the machine
running test, and inspect the pump after the operation.
（1）make the machine running test, the test medium is water or mud, cylinder liner
should be minimum diameter, the air charging pressure of discharge pulsation
dampener reaches the regulated value ≤4.5MPa (650psi)..
（2） the test pressure should reach 70% of the rated highest pressure, not less than
25 Mpa. Grading test can be a total running time of 4 h, the highest test pressure rated
pump stroke running time is 15 min.
（3）the relief valve in accordance with the rating for 20 ~ 25 Mpa to start trials.
（4）check the project including but not limited to：
(4.1) power end bearing and lubricating oil temperature rise of less than 45 ° C
(4.2) fluid end without leakage, power end without oil leakage, air bag without
leakage.
(4.3) the machine has no abnormal sound and abnormal vibration impact.
(4.4) gear meshing contact spots along tooth width direction should not be less than
60%, along the depth direction should not be less than 40%, cannot have abnormal
sound during running.
(4.5) the relief valve open error should not be more than 40%.
10.2.5.4 Attached list
Table 4. Main bolt tightening torque
Torque of the fluid Torque of the Installation
No. Spec.
end high pressure power end low positions
- - 33
area pressure area
N.m N.m
Crankshaft
1 3-8UN（bolt） 13210
assembly
Crankshaft
2 1 1/2-8UN（nut） 2134～2202
assembly
Crosshead
3 3/4"-10（bolt） 290～320
assembly
Crosshead
4 1"-8（bolt） 500～550
assembly
Fluid end
5 1 1/4"-8UN（nut） 1287～1355
assembly
Fluid end
6 1"-8UN（nut） 500～550
assembly
Fluid end
7 1 1/2"-8UN（nut） 2134～2202
assembly
Hydraulic
8 1 "-8UNC（bolt） 348 cylinder
assembly
Hydraulic
9 1 1/4"-8UN（bolt） 535 cylinder
assembly
Hydraulic
10 1 1/2"-8UN（bolt） 785 cylinder
assembly
Table 5. Main corresponding parameters

nominal
diameter(m corresponding parameters
m)
No limit of Rema
location less
. tolerance maintenance rk
more than
code （mm）
than or
equal property
fitting
prope
rty“+”
means
cleara
Drive nce，
shaft and -0.025/+0.052 “-”
1 150 180 n6 -0.077~-0.027 0
bearing +0.027 means
inner race interf
erenc
e
（sa
me
below
- - 34
）
type
3000
Drive
bearin
shaft and -0.03/+0.06
2 180 250 n6 -0.09~-0.031 0 g
bearing +0.031
includ
inner race
ing
Ф300
type
3000
Drive
bearin
shaft and +0.054
3 315 400 G6 +0.018~+0.094 +0.12 g
bearing +0.018/-0.04
includ
seat
ing
Ф300
Drive type
shaft and +0.06 2000
4 400 500 G6 0.02~0.105 +0.13
bearing -0.012/-0.045 bearin
seat g
Drive type
shaft and 2000
5 315 400 H7 +0.057/-0.04 0~+0.097 +0.12
bearing bearin
seat g
Drive
shaft and
6 400 500 H7 +0.063/-0.045 0~+0.108 +0.13
bearing
seat
Drive
H7/ +0.046/+0.169
7 shaft and 225 250 -0.169~-0.094 -0.06
S6 +0.140
gear
parts
Drive pump
H7/ +0.052/+0.190
8 shaft end 250 280 -0.19~-0.106 -0.06 use
S6 +0.158
and gear H8/m
7
Drive
shaft end
H8/ +0.046/+0.06
9 and holes 180 250 -0.06~+0.015 0.04
n7 +0.031
of wheel
disc
crankshaft
and
-0.05/+0.22
10 connectin 500 560 r7 +0.27~-0.15 -0.08
+0.15
g rod big
bearing
- - 35
crankshaft
and
-0.05/+0.225
11 connectin 560 630 r7 -0.275~-0.155 -0.08
+0.155
g rod big
bearing
crankshaft
and
-0.075/+0.255
12 connectin 630 710 r7 +0.175
-0.33~-0.175 -0.10
g rod big
bearing
10.2.6. Storage
(1) Prepare for storage if the pump is stopped more over one week. Mud inside valve
chamber and liner should be clear out completely and washed cleanly before storage.
Lift up fluid end, make pump tilt to power end, drain all the oil inside oil groove and
oil sump, then wash them completely. Finally, remove pipe plug for oil sump, install
one 90° elbow with head down, cover by one iron net for air ventilation to prevent
vapor condensation.
(2) Before storage, all bearings at power end and all inner and outer machined
surfaces of power end and fluid end must be smeared with antirust oil. Exposed pipe
opening shall be blocked up with cover plate.
(3) During storage, it shall be placed on dry, ventilated and flat ground without water
accumulation. It shall be covered with tarpaulin if being put outdoors.
(4) Air pressure in discharge pulsation dampener shall not exceed 0.2MPa when
stored.
11. Possible troubles of drilling pump and troubleshooting
11.1. Troubles and troubleshooting of fluid end

Troubles Reasons Troubleshooting
1. Suction pipe is not
1. Mud pressure on 1. Screw down flange bolt of
sealed well and air
gauge drops, mud suction pipe or replace seal
enters pump.
displacement decreases gasket.
2. Suction filter screen is
or no mud displacement 2. Clean suction filter screen
completely blocked.
2. Mud discharge 1. Piston or valve is 1. Replace damaged piston
unevenly, pressure worn seriously or 2. Replace damaged valve
fluctuate badly, damaged. 3. Replace guide sleeve
abnormal sound in 2. Valve is clamped by
- - 36
cylinder guide sleeve
3. Suction pipeline has 1. Air enters hydraulic 1. Screw down flange bolt of
abnormal sound cylinder. suction pipe or replace seal
gasket.
2. Tighten cylinder cover and
valve cover or replace seal
ring
4. Strenuous knock 1. Piston nut loosens. 1. Screw down piston nut.
sound at liner. 2. Gland of cylinder 2. Screw down liner gland.
cover loosens. 3. Handle as per the factors
3. Water attack due to result in bad suction
unfavorable suction.
1 Valve cap and cylinder
5. Display holes at
lid are not screwed 1 Screw down valve cap and
sealed positions of valve
down. cylinder lid.
cap, cylinder lid and
2. Sealing ring is 2. Replace sealing ring
liner leak mud.
damaged.
6. Air cannot be filled in 1. Charging joint is 1. Clean the inflating
the discharging pulsation blocked. connection
dampener or is quickly 2. Airbag in pulsation 2. Replace airbag.
leaked. dampener is broken. 3. Repair or replace needle
3. Needle cut-off valve shutoff valve.
is not sealed well.
7. Diesel engine has 1. Discharge filter drum 1. Clean filter drum and
large load. discharge pipeline discharge pipeline.
blocking 2. As per liner diameter and
2. Safety valve wrong regulations. Set discharging
setting, pump pressure of safety valve.
overloading operation.
11.2. Troubles and troubleshooting of power end
Troubles Reasons Troubleshooting

1. High temperature 1. Oil pipe or oil hole is 1. Clean oil pipe or oil hole.
of bearing. blocked. 2. Replace with new oil.
2. Lubricating oil is too 3. Replace bearing.
dirty.
3. Rolling bearing is worn
or damaged.
2. Knock sound at 1. Crosshead guide plate is 1. Adjust gap or replace worn
power end worn. guide plate.
2. Bearing is worn or 2. Replace bearing.
damaged. 3. Screw down guide plate
3. Guide plate loosens. screw.
4. Water attach at fluid end. 4. Improve suction
performance.
- - 37
12. Repair of drilling pump

12.1. Disassembly of fluid end (referring to Fig. 16)
1. Seal ring of cylinder liner 2. Wearable disc 3. Liner flange 4. Liner gland 5. Liner 6.
Locking ring 7. Piston rod 8. Clamp assembly 9. Spray device 10. Seal ring of piston
11. Pison 12. Locknut 13. Valve cap sealing ring 14. Valve cap 15. Valve gland 16.
Discharge hydraulic cylinder assembly 17. Seal ring of discharge pipe 18. Discharge
pipe 19. Suction hydraulic cylinder 20. Valve rod guider 21. Spring guide 22. Valve
spring 23. Valve assembly 24. Suction pipe
Fig. 16: fluid end
Note: Make sure to release pressure inside pipelines to zero in the disconnection of
any high pressure pipelines or hoses.
12.1.1. Hydraulic cylinder
- - 38
(1) Release pressure: before starting any maintenance procedures of cylinders, liners,
pistons or valves, close valves on suction pipelines and discharge pipelines, open
bypass pipe valve to mud tank (see Fig. 17, No.2 gate valve). So the pressure in the
cylinder can be released and the risk of the valve cover and cylinder dismantlement can
be eliminated.
1. Return pipeline; 2. Gate valve; 3. Bracket; 4. Safety valve; 5. Four-way block;

6. Pressure gauge
Fig. 17: discharge manifold

(2) Dismantle discharge pipelines and outlet pipe.
(3) Dismantle connection bolts of suction pipe and cylinder.
(4) Dismantle nuts of joint bolts between cylinder and rack, then the cylinder
module can be removed.
Caution: there is no need to dismantle suction pipe, unless the suction pipe needs
to be replaced. Replace gasket or seal ring together while suction pipe or cylinder
module being replaced.
12.1.2. Piston and liner
(1) Turning: turn the pump to make the crosshead at the proper position as required.
(2) Dismantle connection clamps between piston rod and intermediate tie rod. And
turn pump to depart intermediate tie rod from piston rod. Then use liner hoisting tool to
put liner in, use crane equipped with pump to hold liner, and use hammer to knock
- - 39
liner gland loose, and lift out liner and pull the leading chains to take the liner and
piston from rack top.
(3) There is no need to remove piston core from piston rod when replacing piston
cup, simply remove the circlip and clamping plate in front of piston core.
(4) Piston and piston core’s seal: screw off nuts of piston rod and dismantle piston.
Self-tightening seal ring is set between piston core and piston rod shoulder. Generally,
the sealing ring is not easy to damage, and is not necessary to replace.
12.1.3 Liner gland and wearable plate
After remove the fastening nuts of liner gland, dismantle liner gland and wear
plate.
12.1.4. Valve and valve seat
(1) Dismantle discharge valve and valve seat: dismantle the valve cap by inserting a
round bar or round pipe into the valve gland hole, then remove the valve spring and
valve body assembly, use hydraulic valve seat dismantling tools (supplied with pump)
to remove valve seat.
(2) Dismantle suction valve: dismantle the valve cap by inserting a round bar or
round pipe into the valve gland hole, then remove the cylinder head plug and inserted
plate, finally the valve spring and valve body assembly can be taken out from above or
from the side. Use hydraulic valve seat dismantling tools (supplied with pump) to
remove valve seat.
12.2. Assembly of major components of fluid end (referring Fig. 16)
12.2.1. Assembly of hydraulic cylinder
Lift three hydraulic cylinders up to rack, connect and fasten with bolts. The
cylinders are required to be vertical and paralleled to each other. Afterwards, install
suction pipe and discharge pipe. After adjusting each part well, use torque spanner
respectively to tighten joint bolts between suction pipe, discharge pipe and cylinder to
regulated torque. Finally tighten joint bolts between cylinder and rack to regulated
torque. Note: after being washed, threads should be smeared with lube oil or LOCTITE
glue 277. Bolt (nut) pre-tightening torque values are regulated as following: (bolt
- - 40
strength grade is 8.8).
Pre-tightening torque table of bolts and nuts
Bolt nominal
24 30×3 39×3 42×3
diameter 22（7/8）
（1）（1 1/8）（1 1/2）（1 5/8）
mm/（in）
1954－
Pretension torque 321-370 500-550 841－971 2473-2853
2255
N.m/（lb.ft） 237-273 440-508 620-716 1824-2104
1441-1663
12.2.2. Assembly of valve, valve seat and valve cap

Assemble valve body and valve rubber into a whole with press plate and clamp
spring. After confirming no scoring or burrs on valve seat external conical surface,
install valve seat into clean taper hole of cylinder valve seat.
Caution: it is forbidden to smear any oil or grease on external conical surface
of valve seat and taper hole of cylinder valve seat.
Put an intact and old valve body on the valve seat during valve seat assembling,
knocking it several times by iron rod to make sure the reliability and fixability of valve
seat, and then take out the old valve body. Knock the valve seat around evenly by
copper bar if there is no old valve body to ensure that it is closely matched with
hydraulic cylinder.
Smear the grease for valve cap seal ring and put it on the clean hydraulic cylinder
step, assemble the valve cap and valve rod guider and grease the thread surface of
valve cap, and then install the valve cap and tighten it by round bar or circular tube.
12.2.3 Piston assembly and assembly with liner
(1) Assemble piston: carefully install the seal ring between piston and piston rod
when assemble the piston and piston rod. Make sure the tightening torque is 1954～
2255 N.m during tightening the piston nut （1 1/2in）.
(2) Assemble piston and liner: smear lubrication grease on inner surface of liner and
outer surface of piston. Insert piston into liner and make sure the piston rod nut is
towards to the end of liner with outer step.
- - 41
12.2.4. Assembly of piston and liner subassembly
(1) Install clean wearable plate, seal ring and liner flange (liner seat) on hydraulic
cylinder, tightening torque of nut（1in）is 500～550 N.m.
(2) After piston and liner are assembled together, install liner gland and lock ring on
liner and lift it into liner installation chamber of rack, and then tighten liner gland and
the lock ring.
12.2.5. Installation of liner spray device
Adjust the position of spray pipe as per liner dimension during the installation of
the spray device and make sure cooling water shall spray to piston and liner rather than
colliding the piston rod.
12.2.6 Installation of suction pipe and suction air dampener
(1) Install suction pipe: clean flange end face of suction pipe, install seal ring, and
connect to three hydraulic cylinders. Tightening torque of bolt （7/8in）shall be
321～370N.m.
(2) Install suction pulsation dampener: install suction pulsation dampener onto
suction pipeline.
12.2.7 Installation of discharge pipe and discharge manifold
(1) Clean mating faces between discharge pipe and hydraulic cylinder, install seal
ring to hydraulic cylinder. Tightening torque of bolt （1 1/2in）shall be 1954～
2255N.m.
(2) Install discharge 6-way (or 4-way,5-way), discharge air dampener, safety valve,
bypass valve and return line etc as requirements of discharge manifold. The tightening
torque of each bolt and nut should be accord with the regulations of clause 12.2.1.
12.3 Disassembly of power end (referring to Fig. 1)
12.3.1. Disassembly of crankshaft assembly
(1) Dismantle intermediate tie rods: disassemble the connecting bolts between
intermediate tie rods and crossheads and remove intermediate tie rods and stuffing
boxes.
(2) Dismantle left and right crosshead pins, then dismantle middle crosshead pin. It
- - 42
may not be disconnected, but middle crosshead pin baffle, and disconnect the middle
crosshead pin together with crankshaft assembly.
(3) Remove left and right bearing end covers and rear covers, main bearing cover,
and lift out crankshaft assembly. Afterwards, disassemble other parts as required.
12.3.2. Disassembly of pinion shaft
(1) Remove end cover at two ends of pinion shaft, dismantle bearing sleeve bolt at
either end of pinion shaft. Lift out pinion shaft from the rack together with bearing
sleeve with one end dismantled).
(2) If only pinion shaft needs to be removed without dismantling crankshaft
assembly, bearing sleeves at both ends of pinion shaft should be drawn out to make
pinion away from bull gear ring, and then lift out pinion shaft assembly from rack.
(3) To remove damaged bearing without dismantling pinion shaft, bearing sleeves
should be drawn out, and then pull off bearing inner ring from shaft.
12.4. Assembly of main components and parts for power end

12.4.1. Assembly of pinion shaft assembly (referring to Fig. 18)
Fluid
end
1. Key; 2. Pinion shaft; 3. Wearable sleeve; 4. End cover; 5. Seal gasket; 6. Seal
gasket; 7. Bearing sleeve;
8. Retainer ring; 9. Seal gasket; 10. Oil collector; 11. Bolt; 12. Bolt; 13. Oil seal; 14.
Bearing;
15. Washer; 16. Washer; 17. Flange; 18. Bolt; 19. Washer
Fig.18: pinion shaft assembly
(1) After heating bearing inner ring to 100℃-120℃, install it on shaft. The inner
ring should be very close to shaft shoulder and marked as per matched bearings.
- - 43
(2) After heating wearable sleeve to 210℃~220℃, install it on shaft. It should be
very close to bearing with 15° bevel edge end facing outward.
(3) After heating bearing sleeve to 100℃ to 110℃, install matched bearing outer
ring into bearing sleeve. Mark matched bearings.
(4) Pay close attention to identify the left and right ends of shaft, as per bearing
matched marks, install bearing sleeve with assembled bearing outer ring into
mainframe’s installation hole. Then install bolts. Ensure tightening torque of M22 bolt
is 321~370N.m. Note: oil-collecting box should be installed below.
(5) Pinion shaft and another bearing sleeve should be installed from installation hole
at other side of rack.
(6) If the pinion shaft needs to be installed after crankshaft is well installed, first
install pinion shaft into the rack after the pinion shaft has been equipped with bearing
inner ring and wearable sleeve, to ensure pinion and bull gear are engaged and meshed
correctly. Install bearing sleeve equipped with bearing outer ring respectively from two
sides of the rack as per marks.
12.4.2 Assembly of crankshaft assembly (referring to Fig. 19)
- - 44
Fluid
end
1. End cover; 2. Main bearing sleeve; 3. Sealing gasket; 4. Internal retainer ring; 5.
External retainer ring; 6. Connecting rod; 7. Positioning ring; 8. Crank shaft;
9. Positioning ring; 10. Big gear ring; 11. Bolt; 12. Spacer; 13. Main bearing sleeve;
14. Retainer ring; 15. Baffle plate;
16. Bolt, main bearing; 17. Gasket unit; 18. Screw; 19. Stop nut; 20. Bolt; 21. Bolt;
22. Connecting rod bearing;
23. Main bearing; 24. Washer; 25. Locking steel wire; 26. Locking steel wire; 27.
Screw
Fig. 19: crankshaft assembly
（1） (1) Assembly of bull gear ring

Heat bull gear ring to 120℃~140℃, and maintain temperature for 1 hour, then
install to crankshaft and pre-tighten connecting bolt of M39×3 first. After gear has
- - 45
cooled naturally to ambient temperature, tighten connecting bolt again with final
tightening torque of 1954－2255N.m.
（2） (2) Assembly of big end bearing
After connecting rod big bearing inner ring is heated to 110℃ to 120℃, assemble
it on eccentric shaft neck of crankshaft. Then install locating ring.
After big end hole of connecting rod is heated to 100℃ to 120℃, assemble
bearing outer ring of connecting rod into the hole.
内。(Notice: inner ring and outer ring of connecting rod big end bearing must by
matched and installed). And after cooling to ambient temperature, install bearing outer
retainer.
Notice: installation shall be carried out from the middle to two sides.
（3） (3) Installation of crosshead bearing
After heating inner hole at small end of connecting rod to 100℃ to 120℃, install
outer ring of crosshead bearing into inner hole at small end of connecting rod.
Install crosshead bearing inner ring onto crosshead pin after it is heated to 110℃
to 120℃.
（4） (4) Installation of connecting rod
Install connecting rods equipped with the big bearing outer ring onto bearing
inner ring of crankshaft eccentric shaft neck as per matched bearing marks
respectively.
(5) Installation of crankshaft main bearing
Heat main bearing sleeve to 100℃ to 120℃; install main bearing into the bearing
sleeve, heat the unit to 110℃ to 120℃ again, then install the whole unit on
crankshaft main journal. Finally, install shaft end baffle plate.
12.4.3. Installation of crosshead guide plate
Notice: To HHF-1600 drilling pump, upper and lower crosshead guide plates
are not interchangeable. The lower guide plate makes crosshead on the centerline of
frame and upper guide plate is machined such that a certain clearance exists
between crosshead and guide plate. The upper guide plate is very thin and there is a
- - 46
large bevel at the rear and oil hole in middle.
The tightening torque of M20 tightening bolt should be 258N.m~317 N.m for
assembling the upper and lower guide plates.
12.4.4. Installation of crosshead
(1) Crosshead installation: the crosshead can be put into from the front of guide plate
in liner installation space of rack top, can also be put into from the back of power end
inner guide plate of rack. After crosshead installation, install intermediate tie rod.
(2) Adjust coaxiality: check coaxiality of intermediate tie rod and guide board inner
hole when crosshead is at front or back. Coaxiality tolerance is required to be not
greater than 0.20mm. If coaxiality is out of tolerance, it can be adjusted by adding or
removing gaskets as required between the lower guide plate and rack.
(3) Adjust clearance: check clearance of crosshead and guide board inner hole when
crosshead is at front or back. Gap value is required to be 0.45mm to 0.55mm. If it is
out of requirements, it can be adjusted by adding or removing gaskets as required
between the upper guide plate and rack.
12.4.5. Installation of crankshaft assembly
(1) Before the installation of crankshaft assembly, install one wood spacer on each
lower guide plate. As shown in Fig. 20.
(2) Lift crankshaft assembly into rack. Attention: the intermediate connecting rod
should be installed in rack first, and connect the intermediate connecting rod with
crosshead by crosshead pins which already installed the inner ring of crosshead bearing.
Then respectively assemble left and right connection rods and connect to the
crosshead.
- - 47
1 2
3 4 5
1. Connecting rod; 2. Upper guide plate; 3. Spacer; 4. Lower guide plate; 5.
Crosshead
Fig. 20: schematic diagram of guide plate spacer
(3) Gap adjustment of main bearing

As shown in Fig. 21, add steel gasket of 0.50mm at the joint face between main
bearing cap and rack, then put lead wire of no less than 2mm at the centre between
main bearing cap and main bearing sleeve. Pre-tighten it as per the pre-tightening
torque requirement of main bearing bolts, then loosen bolt and remove main bearing
cap, and measure pressed lead wire’s thickness. The pre-tightening redundancy of
main bearing cap is 0.06mm~0.10mm. The actually required gasket thickness is ＝
0.50mm-pressed lead wire’s thickness-pre-tightening redundancy of main bearing
cap (0.06~0.10mm).
12.4.6 Install rear cover, crankshaft main bearing side cover and crosshead side cover.
- - 48
4 5
3 6
(0.60mm)
2 7
1
(0.50mm)
1. Adjusting gasket; 2. Main bearing cover; 3. Lead wire; 4. Main bearing bolt; 5. Main
bearing; 6. Main bearing sleeve; 7. Crankshaft
Fig. 21: gap adjustment drawing of main bearing
12.5. Replacement of discharge pulsation dampener

Replace air bag of discharge pulsation dampener as per the following steps:
(referring to Fig. 22).
- - 49
1. Sealing ring; 2. Bottom plug; 3. Air bag; 4. Housing ;5. Cover; 6. Tee; 7. Joint; 8.
Pressure gauge cover; 9. Exhaust valve;
10. Pressure gauge; 11. Shutoff valve; 12. Washer; R1. Stud; R2. Nut R3. Stud; R4. Nut
Fig. 22: discharge pulsation dampener
12.5.1 Confirm the system pressure has been released completely (see it in the
preceding).
12.5.2. Remove cover (5) and insert a stick into the space between air bag and shell
body. After flattening remove the air bag from the top.
12.5.3 Inspect if the air bag and the bottom plug are in good condition. In case of
damage, replace with new air bag and bottom plug.
12.5.4. When installing a new air bag, first flatten it and curl it up to a spiral shape to
install it from the top of the housing. After that, confirm that the air bag is close to the
housing, and then install new seal ring of the air bag neck to the housing body seal
shoulder and smear lubrication grease on the inside of the neck.
12.5.5. Install cover 5 and do not deform the air bag.
- - 50
12.5.6. Tighten nut (R2) and make its pre-torque is 1954 to 2,202N.m.
12.5.7. Inflate as per section 10.1.1.5 in this manual.
13 HHF-1600L Drilling pump (single pump) factory matching range

(1) Whole machine comprises main machine of pump, components of discharge
system, spray pump assembly, KB-75 discharge pulsation dampener, safety valve and
pressure gauge.
(2) Rubber seal component which shall be replaced once and a set of special tools
for disassembly and assembly will be provided along with machine.
(3) Assemble the6 3/4" bi-metal liner and piston in the pump if the customer has no
special requirements, the spray pump is driven by pinion shaft of pump, and install
pressure lubrication oil pump as a method of concealment.
(4) Any special requirements should be specified when ordering.
14 Random tools
No. Code Drawing No. Description Spec./model Qty. Unit
1 1200360295 HTNB101.05 Sleeve: 3 5/8'' 3 5/8" 1 pc

Stress applying pc
2 1200360265 HTNB101.11 24" 1
rod: 24''
pc
3 1300008131 JB/T7334 Chain block 0.5t×3m 1
Transition taper pc
4 1200360263 HTNB101.13 1
sleeve
pc
5 1200360271 HTNB101.14 Clamp sleeve 1
pc
6 1200360287 HTNB101.16 Bolt 1-8UNC-2Ax160 4
Inner hexagon pc
7 1900000023 5/8" 1
spanner
pc
8 1200360284 HTNB101.18 Sleeve 1 11/16" 1
Inflation hose pc
assembly,
9 1200353524 HTNB021.11.00 1
pulsation
dampener
pc
10 1200360304 HTNB101.02.00 Liner lifting tool 1
pc
11 1200360293 HTNB101.03 Sleeve: 2 3/8'' 1
pc
12 1200360296 HTNB101.04 Sleeve: 2'' 1
Extended rod: pc
13 1200360274 HTNB101.08 1
19 5/8''
pc
14 1200360298 HTNB101.09 Extension bar: 8'' 1
- - 51
pc
15 1200360290 HTNB101.10 Joint: 1'' 1
pc
16 1300008128 SYB-2 Manual pump SYB-2 1
pc
17 1200360273 HTNB101.15.00 Long sleeve 1
pc
18 1900001610 GB/T4388 Solid wrench 2 3/8" 2
Double offset pc
19 1900001058 GB/T4388 2 3/8" 2
ring spanner
Chain pipe pc
20 1300005431 QB/T1200 900mm(36") 1
wrench
pc
21
1200520242 NB018.04.03 Valve cap rod 1
Hydraulic valve pc
22 HTNB164.07.01.00
1200578824 puller 110-ZM60 1
pc
23
1200360292 HTNB101.06 Sleeve: 1 1/2'' 1
pc
24
1900001889 GB/T3390.1 Socket spanner 30mm 1
Note: use No. 17 (sleeve: 1 11/16") if adopt the discharge five-way assembly structure,
and use No. 7 (sleeve: 1 5/8") if adopt discharge elbow pipe assembly.
15. Spare parts
1 1300045965 GB/T3452.1 O-ring 200×7 6 pc
2 pc
1200357864 NB100.05.31 Piston sealing ring 3
3 pc
1200356502 NB100.02.19.00 Locking nut 3
4 pc
1200357797 NB100.05.14 Liner sealing ring 6
5 Hydraulic cylinder pc
1200578416 HTNB164.06 3
sealing ring
6 Valve cap sealing pc
1200578430 HTNB164.05 6
ring
7 pc
1300000281 GB/T3452.1 O-ring 95×5.3 3
8 pc
1300045964 GB/T3452.1 O-ring 190×7 3
9 pc
1300000262 GB/T3452.1 O-ring 345×7 3
10 pc
1200357865 NB100.05.32.01 Capsule 1
11 pc
1200357896 NB100.05.24.05.00 Piston 6 3/4" 6 3/4" 3
12 pc
1200357876 NB100.05.11.00 Valve assembly 7# 6
13 pc
1200357787 NB100.05.10 Valve spring 6
- - 52
14 pc
1200435740 NB008.01.03 Valve rod guider 6
16. Recommended one year spare parts list

Recommended one-year spare parts list for main body of drilling pump
Drawing No.
No. Code Description Spec. Qty. Unit
(code)
Main body
1. Frame assembly
1 1200358889 NB100.01.05 Screw plug 4 pc
pc
2 1200358892 NB100.01.07 Gasket (III) 2
pc
3 1300091365 Ball valve Q11F-16-NPT1 1/4" 2
2. Crankshaft assembly
Sealing
4 1200356486 NB100.02.03 6 pc
washer
3. Pinion shaft assembly
Sealing pc
5 1200355916 NB100.03.05 6
washer
Sealing pc
6 1200355917 NB100.03.06 6
washer
Sealing pc
7 1200355924 NB100.03.09 6
washer
8 1200355939 NB100.03.11 Oil seal 9.125"x10.375"x0.625" 12 pc
4. Crosshead assembly
9 1200356414 NB100.04.06 Oil seal ring 6 pc
10 1300000363 GB/T3452.1 O-ring 190×3.55 12 pc
11 1200356415 NB100.04.07 Two-lip seal 5"x6.25"x0.625" 18 pc
Sealing pc
12 1200356417 NB100.04.08 6
washer
13 1200356420 NB100.04.11 Mudguard 6 pc
14 1300000200 GB/T3452.1 O-ring 125×7 9 pc
15 1200356424 NB100.04.14 Gasket 6 pc
16 1300018406 CCK-1250 Oil seal 127×159.54×16 6 pc
17 1300000346 GB/T3452.1 O-ring 160×7 9 pc
Lower guide pc
18 1200356425 NB100.04.15 2
plate
Intermediate pc
19 1200356421 NB100.04.12 2
tie rod
5. Fluid end assembly
20 1300045965 GB/T3452.1 O-ring 200×7 6 pc
Piston pc
21 1200357864 NB100.05.31 3
sealing ring
NB100.02.19. consumptive
22 1200356502 Locking nut /
00 part
Liner sealing consumptive
23 1200357797 NB100.05.14 /
ring part
- - 53
Hydraulic
24 1200578416 HTNB164.06 cylinder 3 pc
sealing ring
Valve cap consumptive
25 1200578430 HTNB164.05 /
sealing ring part
26 1300000281 GB/T3452.1 O-ring 95×5.3 3 pc
27 1300045964 GB/T3452.1 O-ring 190×7 3 pc
28 1300000262 GB/T3452.1 O-ring 345×7 3 pc
29 1200449821 NB100.05.15.02 Inner sleeve 3 pc
30 1200357865 NB100.05.32.01 Capsule 1 pc
Bimetal liner consumptive
31 1200520701 NB100.05.21.01 5 1/2" /
5 1/2" part
Bi-metal consumptive
32 1200520702 NB100.05.21.02 6" /
liner 6" part
33 1200520705 NB100.05.21.03 6 1/4" part /
6 1/4"
34 1200520704 NB100.05.21.04 6 1/2" part /
6 1/2"
35 1200520706 NB100.05.21.05 6 3/4" part /
6 3/4"
Bi-metal consumptive
36 1200520703 NB100.05.21.06 7" part /
liner 7"
consumptive
37 1200357888 NB100.05.24.01.00 Piston 5 1/2" 5 1/2" /
part
consumptive
38 1200357890 NB100.05.24.02.00 Piston 6" 6" /
part
consumptive
39 1200357892 NB100.05.24.03.00 Piston 6 1/4" 6 1/4" /
part
consumptive
40 1200357894 NB100.05.24.04.00 Piston 6 1/2" 6 1/2" part /
consumptive
41 1200357896 NB100.05.24.05.00 Piston 6 3/4" 6 3/4" /
part
consumptive
42 1200357898 NB100.05.24.06.00 Piston 7" 7" /
part
Valve consumptive
43 1200357876 NB100.05.11.00 7# /
assembly part
44 1200357787 NB100.05.10 Valve spring 6 pc
Valve rod
45 1200435740 NB008.01.03 6 pc
guider
Note: user can choose proper bi-metal liner and piston as spare part as per requirements of drilling
technology.
6. Power end lubrication assembly
Sealing pc
46 1200357722 NB100.06.15 2
washer
Check valve pc
47 1300001032 2
S15A1/2
Overflow pc
48 1300009209 valve 2
YYFJ-L20
2S gear oil pc
49 1300000858 1
pump
- - 54
Pressure pc
50 1300007486 Y-60-Ⅰ 0-1.6Mpa;UN9/16"-16 1
gauge
NB100.06.20. Oil filter pc
51 1200357736 1
00 assembly
7. Other
Sealing pc
52 1200358896 NB100.08 6
washer
Sealing pc
53 1200358901 NB100.10 6
washer
54 1300007562 Rubber strip 40x10x5800 2 pc
Note: when order, indicate mud properties (specific gravity, property, mud
temperature) if specific gravity of mud exceeds 1.5g/cm^3 or oil base, or mud
temperature exceeds 70℃.
- - 55
- - 1

HHF-1600L Drilling Pump (Main Body) User Manual

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HHF-1600L Drilling Pump (Main Body) User Manual

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HHF-1600L drilling pump（Main body）

Important safety statements

2. Description of drilling pump

2.1. Purposes and applicability

2.2. Standards for design and manufacture of drilling pump

2.3. Brief working principle

1. Frame assembly 2. Crankshaft assembly 3. Pinion shaft assembly 4. Crosshead

3 Max. liner diameter 7 1/4″（184.15mm）

4 Stroke length 12″（304.8mm）

Rated power Displacement

Note: 1. Calculate as per volumetric efficiency (100%) and mechanical efficiency

3. Overall structure of drilling pump

3.1. Overall structure of drilling pump

1. Frame assembly; 2. Crankshaft assembly; 3. Pinion shaft assembly; 4. Crosshead

3.2. Overall dimensions of HHF-1600L drilling pump

Fig. 3: overall dimensions drawing of drilling pump

4. Structure description of main parts and components

4.1. Power end

Crankshaft is an integral cast eccentric shaft. Three toggles are subjected to

4.2. Fluid end

1. Fixing frame; 2. Connecting pipe; 3. Spray pipe

5.1. Splash lubrication

5.2. Pressure Lubrication

1. Pinion; 2. Big gear ring; 3. Oil pump drive gear

6. Mud suction system

6.1. Suction pipeline

6.2. Suction pulsation dampener

6.3. Suction filter

6.4. Suction pipeline valve

7. Mud discharge system

7.1. Discharge six-way block

7.2. Safety valve

7.3. Pressure relief pipeline

8. Drilling pump device

8.1. Drilling pump device directly driven by diesel engine

8.2. Drilling pump device driven by compound device

8.3. Drilling pump device driven by motor

9. Installation of drilling pump

9.1. Installation foundation

Fig.13: ground installation schematic diagram of base plates

9.2.2. Fixation and installation

1. Pump skid 2. Spacer 3. T-type steel 4. Plate

10. Use and maintenance of drilling pump

10.1. Running of drilling pump

10.2. Maintenance of drilling pump

1. Crosshead; 2. Intermediate tie rod; 3. Two-lip seal; 4. O-ring; 5. CCK

(2.4) Crankshaft NB100.02.08.00 The shaft neck, 1.Crack must be scrapped

(2.5) Connecting NB100.02.06 Crack, 1.Any crack and

(2.6) Crosshead NB100.04.01 Work surface 1. Scrap if crack or wear >

Table 5. Main corresponding parameters

11. Possible troubles of drilling pump and troubleshooting

11.1. Troubles and troubleshooting of fluid end

11.2. Troubles and troubleshooting of power end

Troubles Reasons Troubleshooting

12. Repair of drilling pump

1. Return pipeline; 2. Gate valve; 3. Bracket; 4. Safety valve; 5. Four-way block;

Fig. 17: discharge manifold

12.2.2. Assembly of valve, valve seat and valve cap

12.4. Assembly of main components and parts for power end

（1） (1) Assembly of bull gear ring

(3) Gap adjustment of main bearing

12.5. Replacement of discharge pulsation dampener

13 HHF-1600L Drilling pump (single pump) factory matching range