Know your Triplex Mud

pump series „TPK“

Service & Maintenance Handbook TPK © WIRTH 11
INTRODUCTION
This service & maintenance manual contains technical
information and all of the operating and maintenance
instruction. It should be read as a guidance and will ensure
that your WIRTH TPK MUD PUMP remains in prime
condition with efficient performance and reduced machine
downtime.
GENERAL INFORMATION
The pump may only be used for the purpose indicated in
the order and in the quotation respectively. Each other
application is considered as being not in accordance with
the purpose provided. The manufacturer does not assume
any liability for damages caused by an inappropriate
application.
The guarantees given by WIRTH are stipulated in the
Conditions of Supply. Guarantee claims are only justified if,
in spite of adherence to the operating instructions, defects
to be attributed to WIRTH are caused at the pump.
Guarantee claims are to be advised immediately after
discovery of the defect to the manufacturing works,
indicating pump number and order number.
If defects are remedied by the customer or a third party
without consent of WIRTH, Messrs. WIRTH are not obliged
to accept claims.
The pump may only be operated with parts supplied by
WIRTH. We do not assume any guarantee for products
from other suppliers.
For structural and specialist repairs it is recommended that
WIRTH technicians are mobilized for this work. It is further
recommended that periodic inspection (with operator client
agreed frequency) be performed by said technicians.

2 Service & Maintenance Handbook TPK © WIRTH

Content
INTRODUCTION ................................................................2
GENERAL INFORMATION ..................................................2
VENDOR CONTACTS ..........................................................4
GENERAL SAFETY ..............................................................5
PUMP SAFETY MEASURES BEFORE ANY MAINTENANCE
WORK ................................................................................6
POWER END.......................................................................7
FLUID END.........................................................................7
FLUID END.........................................................................8
INSTRUCTION FOR OPERATION .....................................10
OIL AND WATER REQUIREMENTS ...................................10
Lubrication Equivalents...................................................11
Gear Lubrication..............................................................13
CHAIN LUBRICATION SYSTEM ........................................16
GEAR AND CHAIN LUBRICATION SYSTEM DRAIN ..........16
LINER SPRAY COOLING SYSTEM.....................................18
Removal & Installation of Valve Closures .......................20
Removal and Installation of Valve Seats ........................23
Removal & Install. of Pistons & Piston Rods...................24
Removal & Install. of Pistons & Piston Rods...................25
Removal and Installation of Cylinder Liners ...................28
Removal and Install. of Pressure Connection .................31
Removal & Install. of H.P. Discharge Strainer ................31
Removal & Install. of H.P. Discharge Strainer ................32
Maintenance Check Tables ..............................................34
Main Service Check Table................................................34
Lubrication Check Table ..................................................36
Weights Main Components (kg)......................................37
Tightening Torque of Screws (Nm) .................................38
Pressure Values for Hydraulic Tool .................................39
Performance Chart TPK 2200 ..........................................40
Performance Chart TPK 2000 ..........................................41
WIRTH TPK 7 ½" x 12"/2000 MUD PUMP ......................41
Wear Limits & Tolerances................................................43
Bearing Clearance (when new) .......................................43
My Notes..........................................................................45

Service & Maintenance Handbook TPK © WIRTH 3

SAFETY RULES
• DURING PUMP OPERATION, PROTECTION DEVICES
SHOULD NOT BE DISABLED OR REMOVED.
• CURRENT OPERATING INSTRUCTIONS SERVE AS
DIRECTIVES FOR ASSEMBLY, OPERATION, SERVICING
AND REPAIR OF WIRTH PUMPS.

VENDOR CONTACTS
Technical assistance concerning any aspect of this
equipment can be obtained from:

Division Oilfield & Pumps

Wirth Maschinen und Bohrgeräte Fabrik GMBH
P.O box 1327
D-41803 Erkelenz
Germany

Telephone: 49-2431-83-0
Fax: 49-2431-83-267
E Mail: mailto:info@wirth-europe.com
Home page: http://www.wirth-europe.com/

Contact names:
• Spare parts; Doris Beer
• Technical assistance; Alfred Giessbach,
Hubert Hurtz

4 Service & Maintenance Handbook TPK © WIRTH

GENERAL SAFETY
• FOR ALL WORK ON PUMPS, OBSERVE THE MOST
RECENT PRODUCT ALERTS AND PROCEDURAL
MODIFICATIONS TO PREVENT ADVERSE INCIDENTS.
• ONLY AUTHORIZED AND TRAINED PERSONNEL TO
OPERATE, SERVICE AND REPAIR EQUIPMENT
DISCUSSED HEREIN.
• COMPETENT AND QUALIFIED PERSONNEL ONLY
ALLOWED TO EXECUTE ELECTRICAL WORK
• OPERATING INSTRUCTIONS AND ESPECIALLY SAFETY
INSTRUCTIONS MUST BE READ, UNDERSTOOD AND
RESPECTED BY ALL PERSONNEL WORKING ON
PUMPS
• OPERATING INSTRUCTIONS MUST BE MADE
AVAILABLE TO OPERATING PERSONNEL AT ALL
TIMES.
• PUMPS MUST BE IN A SAFE CONDITION FOR USE
BEFORE PERMITTING PERSONNEL TO OPERATE
SAME.
• OPERATIONAL RESTRICTIONS MUST NOT BE
VIOLATED.
• UNAUTHORIZED MODIFICATIONS AND CHANGES TO
THE PUMP FABRIC ARE NOT PERMITTED.
• IF THE OPERATIONAL OR ISOLATION STATUS OF THE
PUMPS HAS CHANGED, THE PUMP OPERATOR MUST
INFORM THE PUMP CONTROLLER AND MAINTENANCE
PERSONNEL IMMEDIATELY.
• REPAIRS SHALL BE IMPLEMENTED IMMEDIATELY,
FOLLOWING A TECHNICAL OR PUMP OPERATING
NON-CONFORMANCE.
• OPERATING PERSONNEL MUST BE AWARE OF
EMERGENCY PROCEDURES IN CASE OF
EXTRAORDINARY EVENTS (FIRE, ESCAPE ROUTES,
ETC.)
• ACCESS TO EMERGENCY-OFF SWITCHES AND
ESCAPE ROUTES ARE ALWAYS TO BE KEPT FREE.

Service & Maintenance Handbook TPK © WIRTH 5

PUMP SAFETY MEASURES BEFORE ANY
MAINTENANCE WORK
• OPERATORS MUST NOT WORK ON SYSTEM
UNLESS AUTHORIZED AND ASSIGNED TO DO SO
• PUMP MUST BE STOPPED AND ISOLATED
ELECTRICALLY PRIOR TO ANY INVASIVE OR
REPAIR WORK.
• FLUID END MUST BE DEPRESSURIZED BY
OPENING DISCHARGE DRAIN VALVE
• SUCTION AND DISCHARGE DAMPENERS MUST
BE DEPRESSURIZED PRIOR TO ANY WORK ON
THESE ITEMS.
• WORK AREA MUST BE ADEQUATELY LIT TO
ASSURE ALL ROUND VISION.
• SAFE ACCESS MUST BE PROVIDED TO ALL
ITEMS OF EQUIPMENT NOT REACHABLE FROM
FLOOR LEVEL.
• SUFFICIENT COOLING DOWN TIME MUST BE
ALLOWED PRIOR TO MAINTENANCE TO
PREVENT ACCIDENTAL BURNS.
• HYDRAULIC HAND PUMP PRESSURE GAUGE
MUST BE CALIBRATED PERIODICALLY.
• MAINTAIN A GOOD HOUSEKEEPING REGIME
DURING ANY SERVICE / REPAIR ON THE MUD
PUMPS.

6 Service & Maintenance Handbook TPK © WIRTH

POWER END
fig.1
Each mud pump assembly, complete with main drive motor
and all auxiliary equipment, is mounted on a heavy duty
oilfield type skid. Each pump is driven by variable speed
electric motors. The Motors transmits its power via chain
drive to the main drive shaft (1). which is geared directly
to the crankshaft (2). Both are supported at each end by
roller bearings. Each connecting rod (3) is driven by the
crankshaft. The other end of the connecting rod drives the
crosshead (4) through a parallel 4- roller bearing.
Interchangeable slideways (5), are fixed to the crosshead
guide runners which form part of the pump frame. The
crosshead rod (6) is bolted to the crosshead and moves
backwards and forwards with it. The crosshead rod has
two primary functions. It drives the piston rod (9), and
forms a liquid seal in conjunction with the gear case
stuffing box (7). The crosshead rod is connected to the
piston rod by a split coupling (8).
3 2 1
fig. 1 4,5

Service & Maintenance Handbook TPK © WIRTH 7

FLUID END
fig.2

1
Each pump has three identical fluid ends (1). Each fluid end is
supplied with fluid by its own dedicated piston (2). The pump is
single acting, and the fluid is worked by the piston alternatively
drawing fluid into the cylinder liner on the suction stroke and
expelling it on the discharge stroke. Spring loaded valves (3)
automatically determine the required flow path.
The inlet and outlet valve
bonnets (fig. 3) and all of the
component parts therein are
identical and can be
interchanged. The valve bonnets
incorporate a hydraulically
operated bolt tensioning system
which permits rapid and safe
completion and removal of the
flange connections.

fig. 3

8 Service & Maintenance Handbook TPK © WIRTH

Interconnection and sealing
of the discharge valve
housings is achieved with a
telescopic style connection
(fig.4). The connection is
made simply by pushing the
two mating telescopic fittings fig. 4
together. Thus the blocks can
be assembled in series to
form multiple arrangements.

The pressure manifold

(fig. 5) (4), which can be
bolted to either one of the
two end ports on the fluid
end assembly, comprises a
multi-port block arrangement
incorporating a discharge
strainer. The three 41/16" x
10000# outlet connections of
the pressure manifold
provides flexibility for the
discharge pipework and can
be utilised for the high
pressure fluid discharge
dampener, blind block
incorporating a 10000 psi
high pressure indicator. and a
flange to connect to the
discharge pipework.
The remaining end port on
the fluid end assembly can be
capped for high pressure
drain.
The pumps are supplied with
a suction manifold (5). Each
suction valve housing is
connected to the suction
manifold which has an inlet
connection at each end,
fig. 5
4 5
as well as a central inlet
connection. This provides
flexibility for the suction
pipework.
The suction manifold is fitted
with a low pressure dampener.
One end of the manifold is
fitted with a special flange
which comprises a charging
valve and pressure indicator.
The low pressure dampener is
pre-charged, via the charging
valve, with nitrogen, to a
pressure equal to 50% of the
delivery pressure from the mud
pre-charge pump.

Service & Maintenance Handbook TPK © WIRTH 9

INSTRUCTION FOR OPERATION
OIL AND WATER REQUIREMENTS
Prior to leaving the factory, the oil has been drained from
the gear case and from the chain cases, and the cylinder
liner cooling water pipework drained.
1. Gear case oil.
Check the gearing for cleanliness prior to filling with oil.
Volume of oil required for each gear case = 650 litres.
The oil level can be checked by a sight glass at the rear
of the gear frame, or by a dipstick.
Oil specification;
For temperature range:
-1oC to +68oC DIN 51517 part 3 ISO-VG 320
-20oC to +52oC DIN 51517 part 3 ISO-VG 220
Note: Gear Oil must be PREFILTERED to a
minimum of NAS-Class 8, prior to use.
2. Chain case oil.
Check the chains and sprockets for cleanliness prior to
filling.
Total combined oil volume for two chain cases = 250
litres.
Oil specification for all temperatures:
DIN 51517 part 3 ISO-VG 100
Note: Oil may be used as delivered. Only
gear oil requires pre filtering.
3. Cylinder liner cooling water.
Check that liner spray pump discharge valve is open.
Check cooling water tank for cleanliness. Total volume
of cooling medium tank is 370 litres

10 Service & Maintenance Handbook TPK © WIRTH

 SHEL L
Omala Oil 220

(For temperature range:-20oC to +52oC / -1 to +68°C DIN 51517 part 3 ISO-VG 220 / 320)
Omala Oil 320

MOBIL
Mobilgear 630
Mobilgear 632

LUBRICA
KLÜBER

-TION
LAMORA 220
LAMORA 320

SPARTAN EP 220
ESSO

SPARTANEP 320

REDUCTELF
SP 220 / SP 320
ELF

ELF KASSILLA
220 / 320

FALCON CLP 220

FALCON CLP 320
DEA

Trion EP 220
Trion EP 320

Energol.GR-XP
Lubrication Equivalents

220
BP

Energol GR-XP
320
ARAL

Degol BG 220
Dego lBG 320
specified
Mineral

CLP 220

CLP 320
in DIN
51517

(-20°C to
oil as

Power

(-1°C to
+52°C)

+68°C)
end:

Service & Maintenance Handbook TPK © WIRTH 11

 SHEL L
Omala Oil 100

MOBIL
LUBRICA Mobilgear 627
KLÜBER

-TION

LAMORA 100
ESSO

SPARTAN EP 100

REDUCTELF SP 100
ELF

ELF KASSILLA 100

FALCON CLP 100

DEA

Trion EP 100
BP

Energol GR-XP 100

ARAL

Degol BG 100
specified

CLP 100
Mineral

in DIN
51517

Chain
Drive
oil as

12 Service & Maintenance Handbook TPK © WIRTH

 Gear Lubrication
fig. 6
All of the roller bearings and the crosshead guides are
Service & Maintenance Handbook TPK © WIRTH

lubricated by a pressurised lubricating system. Oil is

circulated to all of the bearing surfaces by means of an
electrically driven circulating pump. Manifolds with
adjustable flow indicators are installed in the feed line to
each lubrication point. The flow indicators have a ball
which floats when oil passes so that it gives a clear
indication that the bearings are receiving sufficient oil. The
base of the gear box acts as a sump for oil storage. The
main ring gear is partly submerged in the sump oil and
provides additional splash lubrication, as it throws the oil
around the gear box.
The oil then passes through a water cooled, heat
exchanger, a dual “on line” oil filter fitted with a visual
differential pressure indicator and finally to the adjustable
flow manifolds. A visual pressure indicator as well as a
pressure transmitter are located immediately up stream of
11

the distribution manifolds, thus registering true bearing

lube oil pressure.
Flow to the bearings is confirmed by the flow indicators
throughout the system. Cooling water supply to the cooler
must be shut off during cold weather start up. During the
warm up period, the pressure may rise slightly above this.
In any event, the pump relief valve is set at 10 bar which is
the maximum allowable system pressure.
If the pump discharge pressure exceeds 10 bar during
normal operation, then the system pressure balance must
be checked. First check that the throttle screws on all of
the flow indicators are correctly adjusted. The flow
indicators are provided with a throttle screw that regulates
the flow to each lubrication point. When properly adjusted,
the indicator ball in the sight window should float freely

Service & Maintenance Handbook TPK © WIRTH 13

without bottoming. The adjustment of one flow indicator
has an effect on the others, so that the overall system
balance is achieved by a trial and error procedure. If the
ball bottoms, there is no flow and the bearings will be
destroyed. If the pump discharge pressure remains high
after the flow has been balanced, then the rest of the
system (pump, cooler, oil filter, and pipelines), must be
checked for blockages.
The oil flow path around the lubrication points is described
as follows:
• Oil passes through the flow controllers to the upper
and lower crosshead slide ways, to the crosshead roller
bearing and to the connecting rod big end bearing.
• Each main drive shaft bearing via a separate flow
controller.
• Each crankshaft end bearing via a separate flow
controller.
• All three stuffing box seals via a single common flow
controller.
The first oil change should be after 400 operating hours.
Subsequent oil changes should be at 2000 operating hour
intervals, or six months, whichever comes first.

14 Service & Maintenance Handbook TPK © WIRTH

fig. 6

I Pinion shaft bearing

II Crankshaft bearing
III/IV Crosshead guide, Crosshead bearing
Connecting rod bearing
V Crosshead rod stuffing box
VI Oil level ( sight glass )
VII Pressure transmitter
VIII Oil filter
IX Pressure indicator
X Oil flow indicator with regulation
XI Temperature sensor
XII Liner spray tank
XIII Liner spray flow sensor
XIV Oil heater
XV Oil double filter
XVI Level transmitter

Service & Maintenance Handbook TPK © WIRTH 15

CHAIN LUBRICATION SYSTEM
fig. 7
Both chain drives are lubricated by a pressurised
lubrication system. The lower section of both chain cases
are manifolded together and act as a common sump for oil
storage. One chain case incorporates a visual level
indicator.
Oil is circulated by a positive displacement gear type pump.
Upon leaving the pump, the discharge line divides into two,
to supply each drive chain via an internal sparge pipe,
which distributes oil evenly across the chains, each feed
pipe incorporating a visual flow indicator.
Located immediately after the pump discharge is a
pressure relief valve which limits discharge pressure to 10
bar, so the system is self regulating. The chain lubrication
system does not include an oil filter.
Chain drive lube oil can be used "as delivered". There is no
requirement to filter the oil.
The first oil change should be after 400 operating hours.
Subsequent oil changes should be at 2000 operating hour
intervals or six months, whichever comes first.

GEAR AND CHAIN LUBRICATION SYSTEM

DRAIN
fig 6 & 7
The gear and chain lubricating systems are provided with
individual valved outlets for draining either system. Any
drainage pipework required away from these valves shall
be supplied by others.

16 Service & Maintenance Handbook TPK © WIRTH

fig. 7

I Oil level ( sight glass )

II Pressure transmitter
III Oil flow indicator
IV Temperature sensor
V Oil heater
VI Level transmitter

Service & Maintenance Handbook TPK © WIRTH 17

LINER SPRAY COOLING SYSTEM
fig. 6
The three cylinder liners are cooled by a closed circuit,
water cooling system. The cooling water is circulated from
a stainless steel storage tank located beneath the piston
chamber, by a single electrically driven centrifugal pump,
and delivered to the piston rods via manifold piping and
flexible rubber hoses.
The distribution manifold has three outlet connections to
feed each cylinder liner. Flexible hoses take the water from
the manifold outlet connections to an inlet connection point
on each of the link pieces that connect the piston rod to
the crosshead rod. This end of the hose travels back and
forth with the piston rod. The link piece and the piston rod
have a concentric hole running along their complete length.
Water is continuously supplied along the piston rod where
it is sprayed out radially into the cylinder liner just behind
the piston. The cylinder liner is open ended so that on the
return stroke of the piston, water is swept back into the
casing chambers from where it drains back (by gravity)
into the collection tank below.

18 Service & Maintenance Handbook TPK © WIRTH

Turning the Mud Pump by Hand
The mud pumps can be turned by hand in order to assist with
maintenance routines and operational piston / liner changes.
The procedure is as follows:
Isolate the mud pump and the charge pump from the
electricity supply.
Depressurise and drain down the fluid end to ensure that
the pump is not working against a fluid pressure whilst it is
being turned.
Take off the cover of the drive shaft (exact position is
depending on your particular pump arrangement, details
may be found in the documentation. delivered with your
mud pump) to give access to the drive shaft drive cog. The
drive cog is fitted with a M48 hex screw with 65mm hex
head, which can be used to turn the pump manually.
Using a 65 mm socket in conjunction with 1"square socket
wrench, rotate drive shaft in a CLOCKWISE direction only.
This will turn the main drive shaft through the gears to the
crosshead and the crosshead rod. Always rotate in a
clockwise direction, otherwise the bolt may unscrew.
Depending upon where the piston is on its stroke, it may be
necessary to move it forward, before it can be moved back.
After maintenance / liner change, ensure both extension bar
and socket are removed from the M 48 bolt and the cover
and all fastening bolts are replaced and tightened.

Service & Maintenance Handbook TPK © WIRTH 19

Removal & Installation of Valve Closures
Removal fig.8
Depressurise the fluid end.
Connect the hydraulic hose from the hand pump to the
snap-on connector (1) on the valve closure.
Apply a pressure of 1580 bar to the hydraulic piston (2).
This will stretch the flange retaining studs (3) by a minute
amount and move the upper assembly away from the valve
body.
Unscrew the jacking plug (4) with the socket wrench
provided.
Depressurise the hydraulic piston.
Disconnect the hydraulic hose from the snap-on connector.
Unscrew the valve closure ring (5) with a torque bar.
Remove insert cover (6) with the special pulling tool
provided.)
Remove sealing ring (7).

Items refer to fig.8

20 Service & Maintenance Handbook TPK © WIRTH

 1
4
5

3
8

10

11

fig.8 12 13

Service & Maintenance Handbook TPK © WIRTH 21

Installation fig. 8
Inspect the sealing ring (7) and renew if damaged.
Clean the sealing surfaces on the insert cover, valve body,
and sealing ring.
Install the insert cover (6) complete with sealing ring (7)
and screw plug (8).
Screw in the valve closure ring (5) and tighten with torque
bar.
Connect the hydraulic hose from the hand pump to the
snap-on connector (1) on the valve closure.
Apply a pressure of 1600 bar to the hydraulic piston (2).
This will stretch the flange retaining studs (3) by a minute
amount and move the upper assembly away from the valve
body.
Screw in the jacking plug (4) and tighten it with the socket
wrench provided until it nips against the piston (2).
Depressurise the hydraulic piston. The residual tension
induced into the flange retaining studs (3) by stretching
them, will pull the complete upper and lower assemblies
together, thereby concentrating all of the closing force on
the sealing ring.
Disconnect the hydraulic hose from the snap-on connector

Note:
To avoid damaging the threads and sealing
surfaces, the valve closures must be retightened,
using the above procedure. After two hours running
time, repeat the tightening procedure. Periodic
checks must also be made and the closures should
be tightened as required.

22 Service & Maintenance Handbook TPK © WIRTH

Removal and Installation of Valve Seats
Removal fig.8
Remove the valve closure; insert cover and sealing ring as
described on previous pages
Remove and lift clear by hand the complete valve assembly
comprising valve cone (9), valve spring (10), valve nut
(11) and valve plate (12).
Replace the jacking screw (5) and insert cover (6) and
tighten with the torque bar. It is not necessary to tighten
with the hydraulic pressure.

Note:
Replacement of the valve closure is a safety
precaution to prevent the valve seat from flying out
when it is expelled by hydraulic pressure. This
safety measure must be adhered to.

Connect the hand pump to snap-on connector (13) and

increase the pressure (max 1800 bar) until the valve seat is
expelled.
Depressurise and remove hand pump connector from snap
on connector (13)
Remove the jacking screw, insert cover and valve seat.

Items refer to fig. 8

Service & Maintenance Handbook TPK © WIRTH 23

Installation fig. 8 & 9

Note:
Prior to installing the valve seat, thoroughly clean
the tapered surface of the seat and the mating
taper in the valve body.

Insert two new O-rings into the grooves (1&2) in the

valve seat.
Ensure that the mating tapered surfaces are clean and
dry.

Note:
Do not use oil or grease on the tapers or on the O-
rings.

Insert the valve seat into the valve body and tap them home
using a piece of wood (or similar soft material) and a
hammer.
Positions refer to fig. 9

fig. 9

24 Service & Maintenance Handbook TPK © WIRTH

Removal & Install. of Pistons & Piston Rods
Removal fig. 10 & 11
Lift hinged cover plate allowing access to piston rod
chamber.
Remove the two split couplings (1), which clamp the piston
rod (2) and crosshead rod (3) together.
Move the crosshead rod slightly to the rear so that the link
piece (4) may be removed.

Note:
Never power up the main drive motors to move the
crosshead rod. Always rotate pump manually with
socket wrench as described above.
Remove the link piece (4) It is not necessary to disconnect
the cooling water supply hose from the link piece.
Dismount the end cover plate (5).
Move the crosshead rod (3) forward until it touches the
piston rod (2) and use one of the split couplings (1) to lock
them together.
Move the crosshead rod (3) as far back as it will go. This
will pull the piston rod (2) with it until the piston is drawn
clear of the cylinder liner (6).
Disconnect the split coupling (1) and remove the piston rod
(2) using the on board maintenance crane and certified
slings.

Positions refer to fig. 10 & 11

Service & Maintenance Handbook TPK © WIRTH 25

6

fig. 10

2
3

7
4

fig. 11

26 Service & Maintenance Handbook TPK © WIRTH

Installation fig. 10 & 11
Install new sealing ring to the link piece (4).
Assemble piston-to-piston rod and tighten end nut (7) to a
torque of 1700 Nm.
Grease the piston.
Introduce the piston and piston rod into the cylinder liner
without link piece, paying careful attention to not damage
either component.
Move the crosshead rod (3) forward until it buts end to end
with the piston rod (2) and push the piston rod into the
cylinder far enough to allow the link piece (4) to be
assembled once the crosshead rod has been withdrawn.
Move the crosshead rod back a sufficient distance and insert
the link piece (4). Oil the clamping bolts on the two split
couplings (1) and torque up to 350 Nm.
Replace end cover plate (5)
Replace hinged cover plate over piston chamber.

Note:
The end nut (7) has to be replaced after each
disassembly of pistons!
Positions refer to fig. 10 & 11

Service & Maintenance Handbook TPK © WIRTH 27

Removal and Installation of Cylinder Liners
Removal fig. 12
Remove the piston rods as described on the previous pages.
Connect the hydraulic hand pump to the snap-on connector
(1) on the flange assembly (2).
Apply a hydraulic pressure of 1450 barg. This will stretch the
upper part of the retaining studs (3) by a minute amount
and take the load off the holding down nuts (4).
Unscrew the holding down nuts (4) with special key
provided shown in fig. 13
Release the hydraulic pressure from the system. This
removes all of the tension from the retaining studs.
Unscrew nuts (4 & 5) together as a pair, and remove them
completely.
Attach flange assembly (2) lifting eye to pump maintenance
crane using a certified sling, then pull flange clear of the
cylinder liner.
Use special pulling tool shown in fig.14 to draw the cylinder
liner clear of the fluid end assembly
Use a certified sling to hoist the liner clear of the pump.

2
1

6
8
7
5

3 fig. 12

28 Service & Maintenance Handbook TPK © WIRTH

fig. 13

fig. 14

Service & Maintenance Handbook TPK © WIRTH 29

Installation fig. 12
Clean the cylinder liner, fit a new end seal and grease
it. Clean and grease the bored surface in the pump
frame that mates with the end of the cylinder liner.
Remove and replace wear ring (6) and seal (7) if
damaged.
Install the cylinder liner using a certified sling in
conjunction with the pump maintenance crane. The
liner may require tapping in using a hard wooden
block and a hammer.
Push the flange assembly (2) forward, and screw nuts
on (4 & 5).
Tighten jacking nuts (5) until they make firm contact
with the hydraulic pistons (8). Ensure that jacking
nuts (5) are slackened off and there is a gap of
approximately 1 mm between the jacking nuts and the
flange.
Connect the hydraulic hand pump to the snap-on
connector (1) on the flange assembly.
Apply a hydraulic pressure of 1400 barg. This will
stretch the upper part of the retaining studs (3) by a
minute amount.
Tighten the holding down nuts (4) using the special
tool shown in fig. 13.
Release the hydraulic pressure from the system. This
will induce a tension in the retaining studs, which will
keep the total assembly pulled tightly together.
Install the piston rods as described on the previous
pages.

30 Service & Maintenance Handbook TPK © WIRTH

Removal and Install. of Pressure Connection
Removal fig. 15
Ensure that the pressure manifold and discharge pipe work
is depressurised.
Remove all of the retaining bolts (1) on one of the flanges.
Using a large screwdriver, carefully pinch the free flange
along a distance of about 5 mm so that the two flanges
move together.
Remove all of the bolts (1) on the other flange, with the
exception of the top two.
Support the weight of the flanges, remove the two
remaining bolts and withdraw the flanges as a pair from
between the valve housings.
Installation
Disassemble the two flanges by pulling flange (4) out of
flange (5)
Clean all sealing surfaces.
Put the support-ring (2) and the O-ring (3) over the lip of
the telescopic connection into the ring groove on the flange
(4).
Telescope the two flanges together by pushing one inside
the other.
Install an O-ring (6) into each of the ring grooves on the
flange faces (4&5).
Slide the complete assembly between the two valve
housings and tighten the retaining bolts (1) on each flange.

4
5

2,3

6
1

fig.15

Service & Maintenance Handbook TPK © WIRTH 31

Removal & Install. of H.P. Discharge Strainer
Removal fig.17
Ensure that the pressure manifold and discharge pipe work
is depressurised.
Using special key shown in fig. 16, unscrew and remove the
end cover (1), complete with strainer (2).
Unscrew the strainer (2) from the end cover.
Remove O-ring with backup ring (3) and O-ring (4) and
clean the strainer.

Installation fig.17
Put the plastic backup ring and the O-ring (3) into the ring
groove on the end cover (1). It is important that the
backing ring goes in first otherwise a correct pressure seal
will not be achieved.
Grease the thread on the strainer and screw it into the end
cover.
Install the O-ring (4) into the ring groove in the strainer
flange.
Screw the end cover complete with strainer into the
pressure manifold and tighten with the special key fig. 16.

32 Service & Maintenance Handbook TPK © WIRTH

fig. 16

fig. 17

4 3

Service & Maintenance Handbook TPK © WIRTH 33

34
Maintenance Check Tables
Main Service Check Table

OPP 1 6
ACTIVITY HOURS DAILY WEEKLY MONTH MONTH YEARLY
Inspect bearing housings of drive shaft for
X
noise development during service
Inspect bearing housings of crank shaft for
X
noise development during service
Check lubricant flow at all flow indicators
X
during service
Check holding down bolts and fluid end
X
clamping bolts
Inspect main gear drive (coincident with oil 2000
X
change)
} what ever is first {
Inspect chain drive (coincident with oil
2000 X
change)
Calibrate hydraulic hand pump pressure
X

Service & Maintenance Handbook TPK © WIRTH

gauge
Check all pressure gauges for function &
X
damages / replace if defect
43
OPP 1 6
ACTIVITY HOURS DAILY WEEKLY MONTH MONTH YEARLY
Check all flow indicators for function &
X
damages / replace if defect
Check all level gauges for function &
X
damages / replace if defect

Check / fill water tank of liner spray system X

Check flexible hoses of liner spray system in

all three casing chambers for damages / X
replace if defect
Inspect liner spray pump arrangement for
noise development and abnormal X
temperature increase during service
Load test & re-certify maintenance crane X

Inspection of HP Discharge Strainer X

35 Service & Maintenance Handbook TPK © WIRTH

36
44
Lubrication Check Table

OPP 1 6
ACTIVITY HOURS DAILY WEEKLY MONTH MONTH YEARLY
Check gear case oil level X

Check chain case oil level X

Check red maintenance indicator of
lubrication system filter / replace filter X
element if clogged
Check suction filter of gear box
lubrication for red alert indication / X
replace filter element if clogged
Change gear case oil & check filter 2000 } what ever is first { X

Change chain case oil 2000 X

Grease maintenance crane bearings by
X

Service & Maintenance Handbook TPK © WIRTH

use of a grease gun
 Weights Main Components (kg)

43
kg
Fluid end suction valve housing
275
Fluid end discharge valve housing
575
Fluid end discharge manifold
430
Discharge pulsation dampener (Hydril)
4700
Fluid end suction manifold
460
GE motors
3100
ABB motors for lube systems
99
Chain casing
350

Service & Maintenance Handbook TPK © WIRTH

37
44
38
Tightening Torque of Screws (Nm)

BOLT / NUT HEX NM

Hydraulic valve closure
M36 / 55 2100
Piston rod clamping device
M20 / 32 350
Piston to piston rod
M39 / 60 1700
Crosshead rod to crosshead
M24 / 36 510
Pressure connection
M16 / 24 170
Discharge manifold to discharge
M42 / 65 3200
valve housing
Discharge dampener to adapter
1 1/8”-8UN / 46 1250
Main drive motor holding down
M36 / 55 2000

Service & Maintenance Handbook TPK © WIRTH

bolts
 Pressure Values for Hydraulic Tool

43
Hydraulic pressure (barg)

Tensioning De-tensioning

Valve closure 1580 1600

Liner clamping flange 1400 1450

Suction to discharge valve housing 1580 1650*

Discharge valve housing to gear frame 1580 1650*

*Note:
Max. allowable de-tensioning pressure shall not extend 1700 bar.
At higher pressure the studs are subject to excess elongation and must not be reused.

Service & Maintenance Handbook TPK © WIRTH

39
40
44
Performance Chart TPK 2200
WIRTH TPK 7 ½" x 14"/2200 MUD PUMP
Stroke 14" (355.6 mm)

Liner size inch 7½ 7 6½ 6 5½ 5¼

mm 190.5 177.8 165.1 152.4 139.7 133.35

Max. discharge psi 3829 4395 5111 6000 7137 7500

pressure bar 264 303 352 414 492 517

Volume per stroke gal 8.031 6.997 6.033 5.14 4.32 3.936

Litre 30.401 26.487 22.838 19.46 16.352 14.90

Pump Max Hyd

Speed Input HP GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM
SPM HP
110 2192 1973 883.5 3344 770 2914 663.3 2512 565.4 2141 475.2 1798 433 1639
100 1993 1794 803.2 3040 700 2649 603 2284 514 1946 432 1635 393,6 1490
90 1794 1615 722.9 2736 630 2384 542.7 2056 462.6 1751 388.8 1472 354,3 1341
80 1594 1435 642.6 2432 560 2119 482.4 1827 411.2 1557 345.6 1308 314,9 1192
70 1395 1256 562.2 2128 490 1854 422.1 1599 359.8 1362 302.4 1145 275,5 1043
60 1196 1076 481.9 1824 420 1589 361.8 1370 308.4 1168 259.2 981 236,2 894
50 997 897 401.6 1520 350 1324 301.5 1142 257 973 216 818 196,8 745

Service & Maintenance Handbook TPK © WIRTH

40 797 718 321.3 1216 280 1060 241.2 914 205.6 778 172.8 654 157,5 596

* Based on 90 % mechanical efficiency LPM = Litre / min. ;

and 100 % volumetric efficiency GPM = US-Gallons / min.; HP = Horse power (1 HP = 0.746 kW) ; SPM = Strokes / min.
 Performance Chart TPK 2000

43
WIRTH TPK 7 ½" x 12"/2000 MUD PUMP
Stroke 12" (304.8 mm)

Liner size inches 7½ 7 6½ 6¼ 6 5½ 5¼

mm 190.5 177.8 165.1 158.8 152.4 139.7 133.4

Max. discharge psi 3829 4395 5111 5535 6000 7137 7500

pressure bar 264 303 352 382 414 492 517

Volume per gal 6.881 5.995 5.169 4.779 4.404 3.701 3.372

stroke Litre 26.0 22.7 19.6 18.1 16.7 14.0 12.8

Pump Max Hyd

Speed Input HP GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM
SPM HP

120 2003 1843 826 3126 719 2723 620 2348 573 2171 528 2000 444 1682 405 1532

110 1837 1690 757 2865 659 2496 569 2152 526 1990 484 1834 407 1541 371 1404

100 1669 1536 688 2605 599 2269 517 1957 478 1809 440 1667 370 1401 337 1276

90 1502 1382 619 2344 540 2042 465 1761 430 1628 396 1500 333 1261 303 1149

Service & Maintenance Handbook TPK © WIRTH

80 1336 1229 551 2084 480 1815 414 1565 382 1447 352 1334 296 1121 270 1021

41
42
44
WIRTH TPK 7 ½" x 12"/2000 MUD PUMP
Stroke 12" (304.8 mm)

Liner size inches 7½ 7 6½ 6¼ 6 5½ 5¼

mm 190.5 177.8 165.1 158.8 152.4 139.7 133.4

Max. discharge psi 3829 4395 5111 5535 6000 7137 7500

pressure bar 264 303 352 382 414 492 517

Volume per gal 6.881 5.995 5.169 4.779 4.404 3.701 3.372

stroke Litre 26.0 22.7 19.6 18.1 16.7 14.0 12.8

Pump Max Hyd

Speed Input HP GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM GPM LPM
SPM HP

70 1168 1075 482 1823 420 1588 362 1370 335 1266 308 1167 259 981 236 893

60 1002 922 413 1563 360 1362 310 1174 287 1085 264 1000 222 841 202 766

50 835 768 344 1302 300 1135 258 978 239 904 220 834 185 700 169 638

40 667 614 275 1042 240 908 207 783 191 722 176 667 148 560 135 511

30 501 461 206 781 180 681 155 587 143 541 132 500 111 420 101 383

Service & Maintenance Handbook TPK © WIRTH

25 417 384 172 651 150 567 129 489 119 450 110 417 93 350 84 319
* Based on 92 % mechanical efficiency LPM = Litre / min. ;
and 100 % volumetric efficiency GPM = US-Gallons / min.; HP = Horse power (1 HP = 0.746 kW) ; SPM = Strokes / min.
 Wear Limits & Tolerances

43
Wear limit
Min diameter Max diameter diameter
[mm] [mm] [mm]

Crank Shaft Con Rod Journal 520,000 520,044 520,000

Con Rod large bore diameter 855,000 855,056 855,056
Con Rod small bore diameter 275,004 275,036 275,036
Pinion Shaft Bearing Journal 260,034 260,066 260,034
Crank Shaft Main Bearing Journal 380,004 380,040 380,004
Crosshead diameter 459,550 459,600 459,400
Slide way diameter 460,000 460,166 460,366

43 Service & Maintenance Handbook TPK © WIRTH

44
Bearing Clearance (when new)

Min / mm Max / mm Wear limits / mm

Main Bearing 0,070 0,130 0,140

Eccentric Bearing -0,050 -0,030 -0,030

Crosshead Pin Bearing 0,010 0,040 0,045

Pinion Bearing 0,125 0,195 0,250

Back Lash New
0,460 0,687 0,787
Bull Gear

Note:
We recommend that all bearings and crosshead / slide ways shall be inspected
against damages and wear limits in regular cycles of 12.000 operating hours or
latest after four (4) years operation. If any wear is indicated during the regular

Service & Maintenance Handbook TPK © WIRTH

maintenance cycles, the recommended period shall be reduced.
My Notes

Service & Maintenance Handbook TPK © WIRTH 45

My Notes

46 Service & Maintenance Handbook TPK © WIRTH

My Note

Service & Maintenance Handbook TPK © WIRTH 46