the American AXG (FG
Contents
1. Description Clearance Crankshaft Throw Diameter Stroke 2 25 Crankshaft Pin or Journal OD 2 8743 2 8748 Connecting Rod Crank Clearance Max Total 003 Crosshead Diameter OD ZIM 257 50 Crosshead Cylinder Bore ID 2 7 919 2 7539 Crosshead to Bore Clearance Max Total 0045 Wrist Pin Bushing Bore ID 1 0005 1 0015 Wrist Pin to Bore Clearance Max Total 002 Table 7 Clearance Chart Metric Conversion 1 inch 25 4 mm 1 mm 0 03937 inches NOTE Clearances shown are total diametral values For radial clearance use 2 the value shown Page 36 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 13 0 Trouble Shooting Pumps This chart is designed to aid in the solution of pump and pump system problems Once the problem has been identified work through the possible causes and solutions until the problem has been corrected Symptom Possible Cause Possible Solution No flow from pump e No liquid in reservoir tank e Inlet line valve closed e Inlet strainer is totally clogged with debris e Crankshaft is not turning e Ensure lines are connected and fill tank e Ensure lines are connected and open valve e Clean or replace strainer e Check for power to drive and drive connections Insufficient pressure from pump ONLY e Pump speed is too low e Relief valve improperly adjusted or worn e Insufficient system resistance worn nozzle e Wo2. 10 Torque the valve cover hex nuts or hex plugs to the recommend values listed in the Fastener Torque Requirements Section 11 0 of this manual Page 28 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 10 0 Servicing the Power End 10 1 Replacing Piston Rod Cil Seals NOTE Ensure that all pressure inside the pump fluid cylinder has been bled off before starting any service work CAUTION Check to ensure that the power is locked out and tagged out The piston rod oil seals 9 retain oil in the power end and prevent contamination from entering the power end by way of the piston rods The fluid end and cylinders must be removed as outlined in the previous sections to provide access to these seals 1 Rotate the seal retainer 10 counter clockwise until it is unscrewed from the frame then slide off the rod Use a larger flat head screw driver as shown or use tool PPAM A000396000 2 Pull the seal holder 8 out of the pump frame and slide off of the rod It may be necessary to insert a screwdriver or pointed tool into one of the holes in the seal holder to help extract it from the power frame 3 Remove the seal retainer gasket 11 from the power frame Inspect the seals 9 and note the orientation of the seals prior to removal The seals may now be removed from the seal holder and discarded 4 To rebuild insert new seals 9 in the seal holder 8 taking care to ensure they are oriented in the same mann
3. Pump ALO918BCD Operation And Maintenance Manual Factory Sales Office P O Box 640 736 19th Avenue NE A American St Joseph Minnesota 56374 Mig Company 888 299 3412 Toll Free Quality Mud Pumps and Parts 320 363 7273 Phone 320 363 7274 Fax info american manufacturing com www american manufacturing com ISO 9001 2008 Registered 7k 0266 A American Mfg Company Quality Mud Pumps and Parts Operation And Maintenance Manual For ALO918BCD Pump Summary This is a manual for American Mfg Company ALO918BCD triplex piston pump with ball valves Alternate model versions The standard model comes with left hand pinion shaft and square keyway shaft end Model ALO918BCD R comes with right hand pinion shaft and square keyway shaft end Page 20f 47 AM A American Mfg Company Quality Mud Pumps and Parts ALOY Piston Pump Data Factory Sales Office ISO 9001 2008 Registered P O Box 640 736 19th Avenue NE St Joseph Minnesota 56374 888 299 3412 Toll Free 320 363 7274 Fax 320 363 7273 Phone 7k 0266 info american manufacturing com www american manufacturing com 11 6 BHP Continuous Duty 13 8 BHP Intermittent Duty Pump Model Configuration Number of Pistons Stroke Length Frame Load Rating Pump Weight Direction of Rotation Internal Gear Rotation Intermittent Duty Speed Rating Continuous Duty Speed Rating Ball Valve Max Speed Rating 625 RPM Min
4. Every installation is different and each will have different requirements to ensure safe and successful operation It is the responsibility of the operator to determine the correct start up procedure for each installation 1 Ensure that the drain plug s on the bottom of the pump crankcase have been installed and are tight Ensure that the oil level sight glass if equipped has been properly installed 2 Check the oil level to ensure that the pump is properly filled with non detergent motor oil gear lube or a synthetic oil as described in Table 2 and that the oil has not been contaminated with water or other contaminants NOTE American Mfg Company pumps are shipped with no oil in the power frame and must be filled to the proper level with the proper grade of oil prior to start up 3 If accessible check the piston rods to ensure that they are free from abrasive particles or debris 4 Ensure that the pressure relief valve and all accessory equipment have been installed and properly adjusted Verify that all joints are pressure tight 5 Open the suction line valve to allow fluid to enter pump Prime the fluid cylinder if necessary on the initial start up or after the system piping has been drained The valve covers may have to be cracked open to assist with priming 6 Check to ensure that power is locked out and tagged out Turn the pump over by hand if possible to ensure free unobstructed operation 7 Apply 10 to 20 drops of gly
5. and then remove the three valve covers 49 from the fluid cylinder 5 The cylinder covers 54 allow access for inlet valve removal Remove the cylinder covers as described in section 9 1 steps 1 through 9 Page 26 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 6 For ball valves the balls are not retained in the valve seat I 2c Oe dea The ball can easily be removed from the valve assembly by P LA E di es lifting it out of the open cage portion of the valve seat with TE 1 as Tus American Mfg Company tool PPAM A000239000 Then SRSP remove the valve seat from the fluid chamber 4 hay de i EA X P Ad aS TM O EE lt AMERICAN 7 To remove the valve seat use knock out tool PPAM A000398000 This tool is inserted from the bottom of the fluid cylinder The tool has a step at the end that mates with the valve seat The tool is then stuck sharply with a hammer and the valve is loosened The suction valve seats can be removed first through the cylinder cover The discharge valve seats can be removed through the valve covers Discharge Valve Cylinder Cover hole with cover amp clamp removed poe m Suction Valve in place Fluid Cylinder Body PPAM A000398000 Strike on this end with a hammer a to remove the valve Figure 4 Using the Knock Out Tool Page 27 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 8 Installation
6. e Pump cavitation e Increase suction size or NPSH tion pressure e Air is entering suction line Correct installation to stop leaks fluctuation Piping vibra Same as Pump runs rough above e See above tion e Excessive pressure variation in discharge e Install discharge pulsation dampener e Piping inadequately supported e Install supports at proper locations e Excessive short radius elbows or tees Correct installation to minimize turns and short radius fittings Pump re e Discharge pressure too high e Reduce system back pressure or adjust relief valve quires exces e Plungers or pistons too large e Install smaller plungers to reduce flow ne poser e Speed too high e Reduce speed e Loosen gland Adjustable packing Correct alignment Correctly adjust belt tension e Increase end play e Supply correct voltage Page 38 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts e Air leaking into suction line or stuffing box e Suction inlet insufficiently submerged e Relief valve or bypass piped to suction e Valve damaged by improper installation Symptom Possible Cause Possible Solution Power end e Discharge and or suction pressure too high e Reduce pressure or reduce plunger size overheats e Oil level too high or too low e Adjust to correct oil level over 180 e Contaminated power end oil e Refill with clean oil amp eliminate contamination i UM e Incorrect oil viscosity or
7. 1 4 Neoprene PPFMC A3434N PPEMC R313766 Table 8 Replacement Rubber ltem Numbers Figure 5 Additional Pump Assembly Product Item Numbers Page 42 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 23 219 OIL FILL 1 NPT DISCHARGE mg BOTH SIDES v X PETCOCK OIL LEVE L 11 375 j i 8 375 H 8 062 11 875 2X 7 8 C BORE X 13 64 DEEP 5 00 12 687 4X 1 2 13 TAP 5 8 DEEP MOUNTING HOL E 4 250 12 500 8 500 S 15 1 2 13 T AP 3 4 DEEP 3X 1 1 2 NPT SUCTIO MOUNTING HOL E 1 812 T 0 25 5 813 Figure 6 Pump Mount Bolt Pattern Page 43 of 47 AME A American Mfg Company Quality Mud Pumps and Parts 16 0 Glossary of Commonly Used Terms CAPACITY The total volume throughput per unit of time at suction conditions It includes both liquid and any dissolved or entrained gases For all practical purposes this can be considered the volume flow rate in the suction pipe The standard unit of pump capacity is U S gallons per minute GPM and metric cubic meters per hour m3 hr CAVITATION The state where fluid pressure drops below vapor pressure causing the liquid to begin to change from a liquid to a gas and boil Usually occurs in the chamber between the suction and discharge valves during the suction stroke and often sounds like a mechanical knock Cavitation results in the formation of gas bubbles or cavities in the fluid that cause vibration and d
8. 16 from the power frame 4 Remove the end cap of each connecting rod 4 by unscrewing the two hex nuts that hold each cap to the connecting rod body The cap can be removed from the body by tapping with a rubber mallet on the cap screws to remove them and then tapping on the end cap to loosen it Take care to not damage the threads on the cap screws 5 Slide the two rod bearing halves 5 from each connecting rod 4 Note that these parts sometimes adhere to the pins journals on the crankshaft 2 Page 30 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 6 NOTE Connecting rods and caps are matched sets and must always be re assembled with their original mate and in the same orientation Note the numbered codes stamped on each half of the connecting rod assemblies and make certain they are installed as matched set and in the same orientation when re assembling the pump The ALO918BCD pumps are configured with pinion shafts for internal gear reduction 7 For ALO918BCD pumps with the pinion shaft remove the hex head cap screws 27 the left and right pinion housings 17 and 18 The gaskets 20 may adhere to the power frame surface and can be left in place if they are not damaged 8 The pinion shaft 3 with bearings may then be removed from the drive side by using a brass rod or other soft material and mallet to drive the shaft out Installation Tip Mark the bearing housings and power fra
9. an absolute minimum Avoid short radius 90 elbows use two long radius 45 elbows instead To help isolate mechanical and hydraulic vibrations American Mfg Company recommends the use of flexible pipe couplings or hose connections between the pump and any rigid piping or the use of pulsation dampeners 4 A properly adjusted pressure relief valve or rupture disc must be installed directly downstream of the pump to prevent damage or injuries resulting from over pressure or deadhead conditions The relief valve discharge line must be as large as the pipe outlet of the relief valve Never install valves in the relief valve discharge line or between the pump and relief valve American Mfg Company recommends that the discharge be returned to the tank or drain not back into the pump suction line 5 It is recommended that a start up bypass line and valve be installed to allow flow to bypass the relief valve This allows the pump to start in an unloaded condition no discharge pressure Page 12 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 5 0 How to Start a Pump CAUTION Always take special precautions when starting a pump for the first time or after any extended shutdown Never assume that someone else has properly prepared the pump and system for operation Always check each component of the system prior to every start up The checklist that follows is intended to be a general guide for starting a pump in a typical installation
10. been prepared for storage drain the preservative and lubricating oil mixture from the power end crankcase If the pump has a pinion bearing remove the rear cover and apply recommended crankcase lubricant Refer to Table 2 in Section 6 0 to the pinion bearings Reinstall the rear cover drain plug breather filler cap piston cup seals and any other components that were removed for storage Once these steps have been completed follow the normal pump start up procedures outlined in this manual NOTE American Mfg Company can factory prepare units for long term storage for a nominal fee if specified at the time of order 3 5 Precautions during Freezing Weather Freezing weather can cause problems for equipment when pumping water based fluids that expand in volume when changing from a liquid to a frozen solid state When water is left in a pump fluid end and exposed to freezing temperatures the expansion of the water as it freezes can rupture the fluid cylinder of the pump and cause equipment damage Injury may result when starting equipment that has been damaged Whenever the pump is stored or idle in conditions that are near or below freezing any water based fluids should be removed from the pump The best way to do this is to run the pump for a few seconds with the suction and discharge lines disconnected or open to atmosphere This will clear the majority of the fluid from the pumping chamber as well as the suction and discharge manifolds After
11. grade e Fill with correct oil power com e Misaligned coupling e Correct alignment ponent end e Belts too tight Correctly adjust belt tension life e Pump running backward Correct rotation e Pump located too close to heat source e Remove heat source or insulate power end e Worn or damaged power end bearings e Replace damaged bearings Crankshaft e Drive belts loose and slipping if equipped Correctly adjust belt tension jerks or e System relief valve pressure set too high e Reduce relief valve pressure setting ga in e Discharge line blocked or partially blocked e Clear obstructions from piping system lion Fluid leaking Piston cups are worn e Replace piston cup from pump e Piston to rod o ring damaged e Replace o ring e Fluid cylinder bolts not properly tightened e Properly tighten and torque bolts e Fluid cylinder o rings or gaskets damaged e Replace damaged o rings or gaskets Reduced e Highly abrasive particles in fluid e Install strainer or filter packing or e Packing or piston cups run dry Correct problem amp replace packing or cup piston iz d e Incorrect packing or cups for fluid type e Change to correct packing or cup Me e Inadequate packing lubrication Correct problem and replace packing e Pump was run dry for extended time Correct problem and replace cups e Plunger or rod misaligned to stuffing box Correct alignment e Worn plunger or cup holder e Replace plunger or cup holder e Worn cylinder liner bore e Replace cylinder lin
12. of Ball Valve Seats The suction valve seats must be installed before the discharge valve seats can be installed The following re assembly procedure is applicable for both A Select a new valve seat and check to ensure the taper on the seat is clean B Carefully clean the taper in the fluid cylinder and on the seat with a cleaning solution and a clean cloth Small scratches can be removed with steel wool or 100 grit emery paper Remove all dirt grease oil water or any other contaminants from the surfaces Do not oil the seats or the seating surfaces in the fluid cylinder Confirm that they are dry before installation C Position the valve seat directly over the mating taper in the fluid cylinder D Let the valve seat drop into the taper Check to see that the seat is sitting in the taper properly and not cocked to one side If the seat drops straight it will seize on the taper When correctly seated it cannot be pulled up by hand E Use tool PAM A000398000 to install the valve seats Place the tool on the top surface of the valve seat Strike with a hammer three times to set the valve seat F Repeat steps A through E for the discharge valves 9 After the valves have been replaced American Mfg Company recommends that the valve cover be replaced Install the valve cover with the new gasket 50 in place and install the valve cover clamps 51 over the valve cover studs 52 Replace valve cover and valve cover hex nuts 53
13. reduction pinion shaft and ball valves Drive shaft standard end comes with 1 1 8 diameter shaft and 1 4 square keyway Preferred Input Shaft Rotation Figure 1 ALO9 18BCD Pump Assembly with Pinion Shaft Page 7 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 3 0 otorage Instructions Proper storage of your American Mfg Company pump will ensure that it is ready for service when needed Follow the guidelines below that fit the requirements of your application American Mfg Company pumps come from the factory without crankcase oil and are prepared for storage periods of up to six 6 months in proper environmental conditions Indoor storage in a dry temperature controlled location is always recommended If pumps are to be stored short term less than six 6 months in a severe environment they should be prepared using the procedures outlined in the Short Term Storage for Severe Environments section 3 2 below If the pump is to be stored or is inactive for periods in excess of six 6 months it is necessary to prepare the pump as outlined in the Long Term Storage Section 3 3 Remember that any fluid that poses an environmental hazard or is toxic must be handled and disposed of properly 3 Short Term Storage IF the pump is stored in an indoor temperature controlled environment for less than six 6 months no special steps are required to prepare it for storage As a general rule for pumps in corrosive flu
14. rod bearings 5 in the connecting rod and connecting rod caps Ensure that rod caps are properly assembled with their mating connecting rod Torque the fasteners holding the end caps to the mating rod per the values given in Fastener Torque Requirements Section 11 0 of this manual Use back and forth pattern tightening with a torque wrench After the cap screws are torqued a light strike to the cap with a rubber hammer will help properly seat the rod bearings 24 A dial indicator must be used to properly adjust the endplay of the crankshaft Improper adjustment may result in excessive temperature noise and reduced bearing life American Mfg Company recommends between 002 tight to 003 loose of internal axial clearance end play when properly assembled The final adjustment must be verified using a dial indicator as indicated in the following steps 29 through 32 25 Turn the crankshaft at least two 2 revolutions to ensure the connecting rods 4 are loose and that there is no binding in the rod bearings 5 the wrist pin 6 joints are free and the crossheads move freely in the power frame 1 Tool PPAM A000402000 may be purchased to help turn the crankshaft Page 330147 AM A American Mfg Company Quality Mud Pumps and Parts 26 Move the crankshaft to one side of the power frame using a light tap from a rubber mallet or a pry bar Rotate the crankshaft several turns and repeat the light taps from a rubber mallet or the use of a
15. rod bolts with a torque wrench to ensure they are within specification This should be done in conjunction with oil change Table 3 Maintenance Chart Page 16 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 8 0 Component Parts List To order service parts or see exact component configurations for your particular pump refer to the cross section parts drawing Contact your local American Mfg Company pump distributor or American Mfg Company if you do not have this information Go e Gs Qo C G QOD Ga 09 3 DO ne ee eJ LN x Z XZ X RY a FH ge AZ LIL w i Ne O N P j Vhs p Be T CNN NNN NL Figure 2A Power End Components Page 17 of 47 AME A American Mfg Company Quality Mud Pumps and Parts 3 D 0 69 Gv 85 MMM M NY WS SSS NN SSSSNN CE I Rl z AN E MS S NJ PCG Ips lt N 77 aun CARN Te Figure 2B Power End Components amp 9 96 amp C Page 18 of 47 AMI Quality Mud Pumps and Parts AVI American Mfg Company if H Hu an 4 N S mm AT sss oS i EC C Tf NN REC o0966G6G AT Ad te wee A WV MA NM SIN NI M AE ALS WENU NINE SS Er sat CR G o 19047 AM Page Figure 3 Fluid End Components A American Mfg Company Quality Mud Pumps and Pa
16. 4 2 Mounting Pump to Foundation and Power Source The ALO9 18 pump described in this document must be mounted in a horizontal position only Secure the pump to the mounting surface using the four 4 holes provided in the pump base Check motor or engine rotation direction to ensure that the top of the pump pinion shaft rotates away from the pump fluid end when in operation For units that are V belt driven check the alignment of the sheaves after the unit is installed on its permanent mounting Tighten belts to the proper tension as recommended by the belt manufacturer Verify that the sheaves are in line and parallel to each other with a straight edge CAUTION Never operate the pump without the belt guard securely installed For direct coupled units ensure that the shafts are centered and parallel when the driver is mounted to the pump Follow the coupling manvfacturer instructions for installation procedures and tolerances CAUTION Never operate the pump without a shaft guard securely installed 4 3 Suction Piping Recommendations Poor suction piping practices are a very common source of pump problems To ensure proper operation it is very important to follow good design practice in the installation of the suction system before the pump is operated A small amount of additional planning and investment in the piping system usually provides for better pump performance and longer periods between service requirements It is difficult to diagnose m
17. 40 Shell Rotella T Temperature 38C to 54 C Shell Omala 220 15 0 100 Synthetic SAE 5W 40 Service Shell Rotella T SAE 50 Exxon HD 3 50 wt 5W 40 217 40 Mobil SCH 630 Mobil Trans HD 50 29 9 100 NA Cold Ambient O F to 30 F 20 68 350 Texaco Meropa 68 5W 30 90 0840 Shell amp Rotella T Temperature 18 C to 34 C Shell Omala 68 15 0 100 Synthetic SAE 5W 40 Service Shell Rotella T SAE 20 Exxon HD 3 20 wt 5W 40 12 0 100 BP Vanellus E8 Mobil Trans HD 20 ULTRA 5W 30 10W 30 69 9 100 Mobil SCH 626 10 9 100 NA Frequent 40 150 775 Texaco Meropa 150 Start Stop Operation Specialty Items Internal Rust Cortec VCI 329 Inhibitor External Rust Texaco Metal Preventative Protective Oil L Table 2 Lubricant Recommendations Synthetic lubricants are suggested for high or low temperature service Cortec is a registered trademark of Cortec Corporation St Paul MN Page 15 ot 47 AM American Mfg Company Quality Mud Pumps and Parts 7 0 Inspection and Preventative Maintenance Chart Routine maintenance is an essential part of any successful pump installation Properly maintained American Mfg Company pumps are designed to offer years of trouble free service Regular maintenance and inspection will keep your pump operating at peak performance American Mfg Company pumps have been carefully engineered to minimize maintenance requirements and simplify these tasks when they are required Regular inspections all
18. 5il Clamp Valve Cover PPFMC 1271716 3 19 Petcock PPFMC 1187039 52 Stud Valve Cover PPFMC A5012 6 20 Gasket Pinion PPFMC A5026 2 3 Hex Nut Valve Cover PPFMC 1121511 6 21 Nameplate PPFMC 5262738 1 54 Cylinder Cover PPFMC A5002 3 22 Lube Fitting PPFMC 1100759 3 55 Gasket Cylinder Cover PPFMC 1280025 3 23 Bearing Cone Crank PPFMC 1101242 2 56 Cylinder PPFMC 1272060 B 24 Bearing Cup Crank BEE MG IZ 2257 2 27 Clamp Cylinder PRFMC 1271415 3 25 Bearing Pinion PPFMC 1104444 2 58 Stud Cylinder Cover PPFMC A5011 6 26 Key PREMO USA 3 Stud PPFMC A5009 2 27 Cap Screw Pinion Bearing PPFMC 1100068 12 60 Seal Holder PPFMC 1281655 3 28 Screw PREMO W874 13 2 61 Hex Nut Cylinder PPFMC TI21511 8 29 Cap Screw Back Cover PPFMC 1106910 14 62 Ball PPFMC 1101418 6 30 Set Screw PPFMC 1103470 3 Page 20 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 9 0 Service Procedures American Mfg Company pumps are designed to simplify all required maintenance The following sections illustrate step by step instructions for performing the most common service procedures of a pump Read each section before starting service work on the pump Refer to Figures 2 and 3 for the location of components WARNING Many accidents occur every year through careless use or service of mechanical equipment You can avoid hazards associated with high pressure equipment by always following the safety precautions listed in Section 1 0 Service Tip Press the
19. Check to ensure that the power is locked out and tagged out motor or engine cannot be started 3 To service the piston cup seals 40 approximately 2 feet of clearance is required between the front of the pump cylinder cover 54 and any obstructions If there is insufficient clearance the pump must be removed and relocated to an area where adequate clearance exists Page 21 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 4 To access the piston cup seals 40 the cylinder cover clamps 57 must be removed Remove six of the nuts 61 holding the cylinder cover clamps 57 in place and then remove the cylinder covers 54 Do not remove the two nuts 61 on the opposite corners of the fluid cylinder as they keep the cylinders 56 and fluid cylinder mounted on the pump during this operation Remove the 55 cylinder cover gaskets 5 Using a socket wrench with a long extension remove the hex piston nut 42 from the piston crosshead rod 7 This nut secures the piston assembly to the piston crosshead rod 6 Following the hex piston nut 42 removal use the American Mfg Company piston tool PPFMC A5049 to pull the piston assembly from the cylinder 56 Insert the American Mfg Company piston tool inside the cylinder until flush with the face of the slotted piston retainer nut 43 Twist the tool to engage and lock the tabs of the tool inside the mating slots in the retainer nut 7 Pull the piston ass
20. TRIC EFFICIENCY Volumetric efficiency VE is the ratio of actual pump capacity output to theoretical displacement The volumetric efficiency is affected by the fluid being pumped and the discharge pressure Page 45 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 17 0 Reference Information Use the following section to record key information about your specific pump model Information such as part and serial numbers will be needed when ordering service parts This data may be found stamped on the metal nameplate located on the pump power frame This area may also be used to make notations about special parts procedures phone numbers or other important information related to your pump Pump Model Serial Number Rated Pressure Rated Capacity Rated Speed Notes Page 46 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 18 0 Maintenance Log Date Service By Service Performed Remarks Page 47 ot 47 AMI
21. amage to components when they collapse DAMPENER A device that reduces pressure pulsations in the suction or discharge piping This may be referred to as a suction stabilizer accumulator or surge suppressor DISPLACEMENT The volume swept by all pistons or plungers per unit time This term is typically expressed as gallons per revolution FLOODED SUCTION Implies that the level of liquid in the suction vessel is above the centerline of the suction port of the pump FLUID END The portion of the pump that converts the linear motion supplied by the power end into fluid flow at pressure This may also be called the Liquid End It is called a valve chamber in old literature MECHANICAL EFFICIENCY Mechanical efficiency ME is the ratio expressed as a percentage of pump power output to the pump power input The mechanical efficiency of reciprocating pumps is very high typically 8576 to 90 NPSHa An abbreviation that stands for Net Positive Suction Head Available NPSHA is the total suction pressure including allowance for acceleration head available from the system at the pump suction connection minus the vapor pressure of the liquid at actual pumping temperature NPSHA for a reciprocating pump is normally expressed in units of feet of water NPSHr An abbreviation that stands for Net Positive Suction Head Required This is the minimum total inlet pressure required by the pump for proper operation This value is a function of p
22. any pump problems without the aid of a suction pressure gauge For this reason American Mfg Company recommends that a gauge always be installed in the suction line directly before it enters the pump The suction line from the fluid source to the pump should be as short and direct as possible Use rigid piping non collapsible hose or a combination of both as circumstances require in your installation The suction pipe size Page 1O ot 47 AM A American Mfg Company Quality Mud Pumps and Parts should be at least equal to or one size larger than the pump inlet Long piping runs low suction heads or indirect pipe routing may require even greater over sizing of the suction line for proper operation of the pump A suction and discharge pulsation dampener is recommended to reduce the effects of acceleration head to help when suction conditions are not optimal In some cases it may be necessary to install a booster pump in the suction line of the pump to obtain sufficient pressure for the pump to operate successfully The suction line must be configured so there are no high spots in the line where air pockets can collect These pockets may make the pump difficult to prime and cause rough erratic operation A drain valve or plug should be installed at the low point of the suction line to allow for draining before freezing conditions or for maintenance American Mfg Company recommends that all piping be supported independently of the pump By support
23. aring cones 23 into bearing housing 12 Pull the connecting rod crosshead assemblies 7 from the power frame Mark each connecting rod and crosshead assembly to ensure they are reassembled into the same bore from which they were removed 13 Remove the set screw 30 and slide the wrist pin 6 out of the crosshead 7 if crosshead or connecting rod 4 requires service Keep components matched together 14 Inspect all components for signs of wear or damage and replace if required Carefully check the crankshaft bearing surfaces for pits scratches or other signs of wear The connecting rod bearings should be inspected for deep scratches or the top metal surface worn away 15 Thoroughly clean all parts with solvent and apply a thin coat of oil before reassembly 16 Tapered roller bearing cups 24 must be heated to aid in assembly onto the shaft Always observe proper safety procedures and use heat resistant tools and gloves when handling hot parts There are a number of recommended methods for heating bearings Electric ovens or electrically heated oil baths may be used but only when accompanied by proper thermostatic control Page 32 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 17 To replace the tapered roller bearings on the crankshaft heat the cones to a maximum of 300 F 149 C Slide them down the shaft unit they are fully seated against the shoulder The hot cup may pull away from the shoulder unle
24. bers sssssssssssss ees 42 Figure ALO9 1 8BCD Pump Assembly with Pinion Shaft Figure 2A POW EF End C ODIDOBETU Genieis panse E NM UNUM ODE ucDENOM INCUN UNO 17 Figure 2B Pour ne SE e 1 T E E E ESIET TET 18 Figure 3 RUG RIG lt 0 il E EE T 19 Figure 4 Using the Knock Out Tool 0 ccc e menn 27 Figure 5 Additional Pump Assembly Producis essssssssssssss ee 42 Figure Pura Oli ON asus tee E e rd yauomunises aque te Rd PIN PUN 43 Page 50f 47 AM A American Mfg Company Quality Mud Pumps and Parts 1 0 Important Safety Instructions WARNING Many accidents occur every year through careless use of mechanical equipment You can avoid hazards associated with high pressure equipment by always following the safety precautions listed below AM SHUT DOWN OR DISENGAGE the pump and all accessory equipment before attempting any type of service Failure to do this could cause electrical shock or injury from moving pump parts or components under high pressure Always adhere to Lock Out and Tag Out procedures For mobile equipment be sure engines and hydraulics cannot be accidentally started AMI BLEED OFF ALL PRESSURE to the pump and piping before performing any maintenance on the pump Failure to do so may spray water or chemicals at high pressure or high temperature onto service personnel AM NEVER OPERATE THE PUMP WITHOUT A PRESSURE RELIEF VALVE rupture disc or other type of properly sized over pressure safety
25. carried out after first 100 hours of operation and subsequently after every 4 000 hours or at least every 6 months These intervals may be moditied depending on actual operating conditions This model pump requires 2 1 4 quarts 2 1 liters of oil E S AMIE Oil should be changed when hot to prevent build up of sludge deposits AMI It is advisable to check oil level daily If more than 10 of the total capacity has to be added check for oil leaks AM Do not mix oils of different types even if produced by the same manufacturer AM Never mix mineral and synthetic oils KK AM To avoid the risk of scalding or burns pay attention to oil and power end temperature during an oil change AMI Follow environmental guidelines when changing and disposing of lubricants Page 14 0f 47 AM A American Mfg Company Quality Mud Pumps and Parts Recommended Lubricant Chart Type of Ambient SAE ISO Viscosity SSU Manufacturer Brand SAE ISO Viscosity Manufacturer Brand Service Temperature Grade cSt 40 C Viscosity Name Grade cSt 40 C Name General O Fto 1001F 30 100 550 Texaco Meropa 100 10W 30 90 0 40 Shell Rotella T Service 18 Cto 38 C Shell Omala 100 15 0 100 Synthetic SAE 5W 40 Shell Rotella T SAE 30 Exxon XD 3 30 wt 5W 40 99 1 40 Mobil SCH 627 Mobil Trans HD 30 13 9 100 NA High Ambient 100 F to 130 F 50 220 1 165 Texaco Meropa 68 5W 40 90 0
26. cerin or mineral oil to the pistons cylinders and piston rods to lubricate the packing and seals 8 Make sure that all guards are in place and secure Verify that all personnel are in safe positions and that system conditions are acceptable for operation 9 The pump is now ready to start NOTICE Whenever possible use a bypass in the discharge line to allow the pump to start in the unloaded condition no discharge and pressure Slowly close the bypass line to bring the pump into full load conditions Shut down immediately if the flow becomes unsteady pressure fluctuates or if unusual sounds or vibrations are noted 10 Take temperature readings of the power end and stuffing boxes Do not exceed 170 F 77 C on power end Page 13 of 47 AME A American Mfg Company Quality Mud Pumps and Parts 6 0 Lubrication of Power End 6 Recommended Lubricants Few factors can influence the life of a pump more than the power end lubricant oil Careful selection of the right type of oil for each particular application will help ensure optimal performance from an American Mfg Company pump NOTE Lubricant temperatures should not exceed 170 F 77 C for continuous duty or 180 F 82 C for intermittent duty applications Crankcase temperatures that exceed these limits will cause the lubricant to prematurely break down The result will be poor lubrication and failure of power end components 6 2 Oil Changes Oil changes must be
27. device installed AM ALWAYS USE A PRESSURE GAUGE when operating the pump The pressure must never exceed the maximum pressure rating of the pump or damage may occur This damage can cause leakage or structural damage resulting in injury to personnel AM ENSURE THAT NO VALVES ARE PLACED BETWEEN THE PUMP AND PRESSURE RELIEF VALVE If the pump is started with a closed or restricted valve in line before the pressure relief valve the pump may exceed the rated or designed pressure limits and rupture causing injury to personnel AM USE SHIELDS OR COVERS AROUND PUMPS when pumping hot water chemicals or other hazardous liquids This precaution can prevent the exposure of service personnel to these fluids should leakage occur AM ALWAYS USE GUARDS on all belt drives couplings and shafts Guards can prevent personnel from becoming entangled and injured by rotating and reciprocating parts AM USE EXTREME CAUTION WITH SOLVENTS used to clean or degrease equipment Most solvents are highly flammable and toxic Observe all safety instructions on packaging AM FOLLOW NORMAL ENVIRONMENTAL GUIDELINES WHEN fluids lubricants or solvents are disposed of or spilled AM NEVER MODIFY THE PUMP to perform beyond its rated specifications without proper authorization in writing trom AMERICAN MFG COMPANY Page 60f 47 AM A American Mfg Company Quality Mud Pumps and Parts 2 0 ALO9 BBCD Pump Features The ALO918BCD pump includes the integral gear
28. e A mebintter E er bere auto petrol d E er eges secre MT 17 9 0 Service Procedures e e ene ee nenne e hene nennen 2 9 1 REMOVING MS FIG C ITIIG NE ER 24 9 2 Replacing 1017 MENTION 26 10 0 Se e Ot ENC E E EEE cent tarde ont dei ae 29 10 1 Replacing Piston Rod Oil Seals eee 29 10 2 Replacing Power End Bearings amp Crankshatt cccccccccccceee ce teteceeeeeee eee enbeeeeeeeeeins 30 11 0 Fastener lorgue Requiremeris ececs orte re bette errors rtv beri otto s bid Fassa desea ad 35 12 0 PES 1C E EESTE etu ox ee dodoate seer de opeee ene onan AD RE UE 36 13 0 Trouble Shooting PUMPS 0000 ccc mm nemen 37 14 0 OT ING TF BS EE EEEE ET 4 15 0 Additional Pump Assembly Producis ssssssssssssss ee 42 16 0 Glossary of Commonly Used Terms eee 44 17 0 Reference Information issssssssssssss em e e eene enne 46 18 0 Manendice log Eee ne enone renee ner ter ene I ene Nd REM T M NR AJ Page 40f 47 AM A American Mfg Company Quality Mud Pumps and Parts List of Figures and Charts Table 1 Pipe Pressure o RITE ERE 1 Table 2 Lubricant RECOMMENAATIONS 60 eee ee nnns 15 Table 3 dre Mare e SGI NN EE EE eee eet een 16 Table 4 Component He Mid WUMO STS tale ceresricatenege lt xtsnaaneeonootnsests EE EEEE EE ERREA EEEEEEEEEEEEE EEEE EE En 20 Toble 5 iyice Too lem NUMDE RET EE ET 21 Table 6 Torque Values for Critical Pump Fasteners ee 35 Toble 7 I SS CO eerren ea E E E TEM 20 Table 8 Replacement Rubber ltem Num
29. embly free of the pump using a combination pulling and twisting motion Page 22 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 8 Place the flats on the bottom of the piston holder 41 in a vice or clamp securely Using the American Mfg Company piston tool PPFMC A5049 unscrew the piston retainer nut 43 and remove The piston cup 40 and piston retainer 44 may now be removed Tool PPFMC A5049 is designed with hex nut for using torque wrench to appy proper torque as indicated in 11 0 9 Inspect all parts for damage or unusual wear Ensure that the interior surface of the cylinder 56 is smooth and free of cracks or grooves New piston cups 40 will fail prematurely if installed in liners with damaged bores American Mfg Company strongly recommends that all three piston cups be replaced not just those that show signs of leakage whenever this type of service is performed This will maximize operational time between service intervals 10 Reverse steps 3 through 9 to rebuild the pump after worn or damaged components have been replaced American Mfg Company recommends that all seals and gaskets that are disturbed during the service procedures be replaced This includes the rod seal o ring 45 that is located on the piston crosshead rod shown directly behind the piston assembly Some pump models have the o ring in a groove in the piston holder instead of a separate seal holder Lubricate the piston cups and pi
30. er e Packing gland too tight adjustable e Properly adjust gland nut e Packing gland too loose adjustable e Properly adjust gland nut e Too much packing in box Correct installation problem e Broken or weak spring e Replace spring Reduced e Highly abrasive particles in fluid e Install strainer or filter valve life e Cavitation damage Correct problem and replace damaged valves Correct problem and replace damaged valves e Increase submergence or baffle to stop vortex e Pipe back to reservoir tank e Replace damaged components Page 39 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts Symptom Possible Cause Possible Solution Cracked e Discharge pressure too high e Reduce system back pressure or relief valve fluid cylinder o Hydraulic shock cavitation or entrained air Correct piping system problem or broken e Discharge valve stuck closed e Replace damaged components ini one e Fluid freezing in fluid cylinder e Change procedure to drain fluid when cold e Material or manufacturing defect e Replace defective component e Bolt or nut not properly torqued e Replace fluid cylinder and properly torque e Excessive piping loads on fluid end e Add supports to piping Broken e Discharge pressure too high e Reduce system back pressure or relief valve crankshaft or e Suction pressure too high e Reduce suction pressure or plunger diameter connecting e Fluid freezing in fluid end e Change procedure to dra
31. er as the ones that were removed Do not reuse seals that have been removed from the pump Replace the seal retainer gasket 11 if it shows signs of deformation or damage 5 Wrap tape or other material over the exposed piston rod threads to protect the new seal lips from damage Install the seal retainer gasket then slide the seal holder over the protected threads and into the pump frame Care must be taken to ensure the seal lips are not folded or cut when passing over the ends of the rod 6 Ensure that the gasket 11 and seal holder 8 are in place install the seal retainer 10 and tighten until it bottoms out Do not over tighten as it can damage the seal retainer gasket 7 Remove the protective material that is covering the rod threads Rebuild the remainder of the pump as outlined in previous sections Torque all fasteners as outlined in the Fastener Torque Requirements Section 11 0 of this manual Page 29 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 10 2 Replacing Power End Bearings amp Crankshaft WARNING Disconnect the driver from the pump and ensure that suction and discharge lines are disconnected or blocked and have no pressure applied 1 Removal of the fluid cylinder simplifies crankshaft removal on ALO918BCD models 2 Remove magnetic pipe plug 32 to allow all oil to drain from power frame 1 3 Remove all rear cover cap screws 29 Remove the back cover 15 and back cover gasket
32. er of the pump with the order These numbers can be found stamped on the metal name tag affixed to the power end of every pump By referencing these numbers you can ensure that the components you receive work as intended with your pump Be sure to inquire about any special service tools or complete maintenance kits Page 41 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 15 0 Additional Pump Assembly Products DISCHARG E SURGE CHAMBER FOR 1 NPT P PAM A000524000 Loa EA PRESSURE GAUG P PAM A000380000 DISCHARGE LINE J MA gt ij J HI H UU Replacement Rubbers INT AKE LINE PRESSURE RELIF VALVE PPFMC 3546492 pat i S A own INT AKE SURGE CHAMBER FOR 1 1 2 NPT P PA M A000525000 1 1 2 NPT A Component Description Part Piston Rubber 2 1 4 Carbox Nitrile XNBR PPFMC 5260052 Alternates Component Description Part Piston Rubber 2 1 4 HSN Piston Rubber 2
33. id applications the fluid end should be drained flushed with water or other non corrosive cleanser and compressed air used to blow dry whenever idle 3 2 Short Term Storage for Severe Environments IF the pump has been in service drain any fluid from pump fluid end flush the fluid end with water to clean out any of the remaining pumpage and blow dry with compressed air Pour 1 4 to 1 2 cup of internal rust inhibitor oil described in Table 2 see Recommended Lubricant Chart Section 6 0 into the suction and discharge ports of fluid end and then install pipe plugs in openings Drain the power end crankcase oil and remove the oil fill cap or plug Pour 2 to 1 cup of internal rust inhibitor oil described in Table 2 into the oil fill hole and then install the filler cap Coat all exposed unpainted metal surfaces for example Driveshaft with preservative oil Replace the oil fill cap and then cover the entire pump with a weather resistant covering such as a canvas or plastic tarp 3 3 Long lerm Storage Long term storage is defined as any period when the pump is in storage or idle in excess of six 6 months If the pump has been in service drain any fluid from the pump fluid end flush the fluid end with water to clean out any of the remaining pumpage and blow dry using compressed air Pour 1 4 to 1 2 cup of internal rust inhibitor oil described in Table 2 into the suction and discharge ports of fluid end and then install pipe plugs in o
34. imum Speed 360 RPM Mechanical Efficiency 85 Lubrication System Splash Gravity Return Lube Oil Capacity 2 25 Quarts Lube Oil Type SAE 30 Maximum Fluid Temperature Minimum Fluid Temperature Standard Suction Size Standard Discharge Size Fluid End Material Valve Type Hydraulic Motor Mount ALO918 Horizontal Triplex Piston 3 2 25 Inches 57 2 mm 2800 Ibs 1 270 kg 200 Ibs 90 7 kg Top of Shaft away from head 36 890 RPM Jackshaft 750 RPM Jackshaft 140 F 250 F Capability O F 20 F Capability 1 50 Inch NPT 38 1 mm 1 00 Inch NPT 25 4 mm Cast lron Disc Valve Ball Valve SAE C 4 Bolt with 1 25 14T Performance Rating Pump Capacity Input Speed RPM Pump Displacement Maximum Model Diameter REV Pressure 350 RPM 625 RPM 700 RPM 750 RPM 890 RPM Inch mm Gallon Liter PSI kg cm gpm lpm gpm lpm gpm lpm gpm lpm gpm lpm ALO918 2 25 57 2 0 0323 0 122 700 49 2 11 3 43 20 2 76 22 0 86 24 2 92 28 7 109 Specifications subject to change without notice Horsepower is based on 85 or 90 efficiency Actual application horsepower A do requirements can be calculated using this equation BHP GPM PSI 1714 0 85 Lm A or 0 90 Pump capacities listed are based on 100 volumetric efficiency J v WA ANSB OT UK AS AN M ACCREDITED This document contains American Mfg Company proprietary and confidential REGISTRARS INC _ informat
35. in fluid when cold es e Hydraulic shock due to cavitation Correct piping system problems e Material or manufacturing defect e Replace defective components Power end e Extended operation with failed piston cup e Replace piston cup and improve monitoring oil is con e Hi pressure sprayer nozzle near breather or seals Provide shields to protect breather and seals taminated e Deflector shields are missing or damaged e Repair or replace deflector shields e Crosshead extension seals damaged e Replace oil seals e Excessive capacity in liner wash system e Reduce capacity in liner wash system e Improperly adjusted liner wash nozzle e Adjust liner wash nozzle Page 40 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 14 0 Ordering Parts Service parts are available through American Mfg Company s worldwide network of distributors or from the original supplier If unsure where to purchase parts contact American Mfg Company customer service for the location of an authorized parts retailer in your area Always insist on genuine American Mfg Company replacement parts Use the assembly drawing and bill of material included on pages 17 through 20 with this manual to determine the components and corresponding part numbers required to service the pump Make sure that the model number on the drawing or bill of material matches the model number of the pump requiring parts When ordering parts always reference the model numb
36. ing the piping this way vibrations are reduced and stress on the pump is kept to a minimum The use of elbows nipples unions or other fittings should be minimized Make sure that all joints and connections are airtight Air leaks reduce the capacity of the pump and can result in cavitation rough operation and or loss of prime To help isolate mechanical and hydraulic vibrations American Mfg Company recommends the use of flexible pipe couplings or hose connections between the pump and any rigid piping Always ensure that calculated system Net Positive Suction Head available NPSHa exceeds pump Net Positive Suction Head Required NPSHr by at least 5 feet 1 5 meters of water for proper operation of the pump NPSH requirements for each pump model are provided on the product data sheets available through American Mfg Company or your authorized American Mfg Company reseller American Mfg Company does not recommend using the pump in static lift conditions without prior factory approval 4 4 1 Route the discharge piping in as short and direct a route as possible Use the same pipe size as the outlet of the pump In installations where the discharge piping is in excess of 50 feet 15 meters it is suggested to use the next larger size pipe to minimize friction losses downstream of the pump CAUTION Always use pipe or hose that is designed for your particular pressure requirements Inadequate pressure ratings can allow hose or pipe
37. ion It is loaned for limited purposes only and remains the property of American Mfg Company It may not be reproduced in whole or part or disclosed to third parties without the prior written consent of American Mfg Company The document is to be returned to American Mfg Company upon request and in all events upon completion of the use for which it was used Page 3 of 47 AM A American Mfg Company Quality Mud Pumps and Parts Table Of Contents 1 0 HOC MM SONI ING Ted NETTE T 2 0 ALOS TO GNI 3 0 Seer a e E E QE E E TT T 8 3 1 Short Term Storage cece e m eene e en ree e enne 8 3 2 Short Term Storage for Severe Environments sss 8 SMS feta MI Ware le 1918 RINT TTE DITE 8 3 4 Returning a Stored Pump to Operation cece cece cece eee ee 9 3 5 Precautions during Freezing Weather sssssssssss ee 9 4 0 ASTOR Cudelne NETTE 10 4 euro Mie se oh RENE EE EO IE 10 4 2 Mounting Pump to Foundation and Power Source ssssssssssssseeel 10 4 3 Suction Piping Recommendations sssssssssssss eee lO 4 4 Discharge Piping REGOMMENG GHOMNS secs secco opta eaco iita toni ete teet etre ne eite teer ehe ers 1 5 0 59 16 500 GU ised ate eee E assuage E EE E E E I3 6 0 luon GH ONION FF OWE EN MERECE EE TT are EEr e 14 6 1 Recommended Lubricants een l4 62 e Eds ue E N T E EO S 14 7 O Inspection and Preventative Maintenance Chart 16 8 0 OM FAP Peri TIE oseeconsesser onc
38. me for installation in the original position 9 Remove the hex head cap screws 27 bearing housings 12 gaskets 14 and shims 13 from both sides of the pump Count and record the shims on each side to facilitate assembly The gaskets 14 may adhere to the power frame surface and can be left in place if they are not damaged The bearing cones 23 will remain in the bearing housing Page 31 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 10 To remove the crankshaft on ALO918BCD models work the crankshaft to the left when viewing from the rear opening of the power frame The throws or journals may have to be rotated as the crank is removed to clear the connecting rods Slip the crankshaft end on the right out the back of the power frame and remove The crankshaft should be handled carefully to prevent the critical bearing surfaces from being scratched or damaged 11 Bearing cups 24 may be removed from the crankshaft Bearing cones 23 can be removed from the bearing housing using a puller if a sufficient lip is available for the puller arms to grab An alternate procedure involves running a weld bead around the inside surface of the cup When cool this will reduce the interference between the cup and bearing housing enough to free the cup If either the cup or cone is replaced the corresponding cup or cone should be replaced as they are a matched set Tool PAM AO00401000 can be purchased to press be
39. oved take care to ensure that the cylinders liners do not fall off of the front of the power end and become damaged 5 To remove the piston assemblies refer to the previous section 9 0 6 Inspect all parts for signs of wear or damage Replace parts if required Page 24 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 7 Always replace the cylinder gaskets 46 when the cylinders have been moved or replaced 8 Installation will be the reverse of this procedure 9 Torque all fasteners as outlined in the Fastener Torque Requirements Section 11 0 of this manual Please note that if the nuts 61 on the fluid cylinder studs 58 and 59 are not properly torqued a failure is likely Page 25 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 9 2 Replacing Valves 1 Ball type valves are supplied with the ALO918BCD pump 2 A minimum of approximately 2 feet of clearance is required above below and in front of the pump fluid cylinder to allow valve service without removal of the fluid end If sufficient clearance is not available the fluid end must be removed as outlined in previous section 9 1 and taken to a work shop for valve service The following procedure is written under the assumption that sufficient clearances exist 3 Remove the three suction plugs 48 from the bottom of the fluid chamber 38 4 Remove the six valve cover nuts 53 holding the valve cover clamps 51
40. ow operators to become familiar with normal pump operation so they can recognize the signals of potential problems and schedule maintenance The maintenance chart in Table 3 shown below should be used as a guideline only Many applications will require adjustment of the intervals shown in this chart for severe or unusual operating conditions Interval Component Service Remarks Crankcase Oil Change Drain and refill with new oil after first 100 hours of operation Ensure that the magnetic drain plugs are cleaned to remove debris Break In Period Inlet Strainer Inspect Clean if required The amount of material in the strainer will determine the interval of cleaning Complete Pump Inspect General inspection of pump and system to check for proper operation of equip ment Piston Cup Sets Inspect Check the cylinder liner area of the pump for signs of leakage Replace piston Bf cups if leakage becomes excessive ai i Pump System Flush Required for shutdown when pumping fluids that may harden or corrode the pump if left inside once stopped Crankcase Oil Inspect Ensure that the oil is at proper level and has not been contaminated by pump age or condensation Crankcase Oil Change Drain and refill with new oil Clean magnetic drain plugs 6 Months Stuffing Box Inspect Check the stuffing box bolts with a torque wrench to ensure they are within 4 000 Hours specification Connecting Rod Bolts Inspect Check the connecting
41. p to leak or possibly allow the pump to fail Always use a calibrated torque wrench during the installation of all critical fasteners listed in Table 6 below Values are in foot pounds Ft lb and Newton meters N m Typical sizes are shown in Table 6 below Refer to Table 7 for other sizes that may be used depending on application Power End Torque Values Item Component Description Size Ft lb N m 4 Connecting Rod Bolts A438 7 16 45 61 43 Piston Assembly Nut 750 3 4 35 47 42 Piston Rod Hex Nut 500 1 2 35 47 28 Bearing Housing Screws 375 378 25 34 28 Pinion Housing Screws 375 13 8 25 34 29 Back Cover Bolts 10723019 48 20 27 27 Cross Head Set Screw 313 97 T6 10 14 61 Cylinder Attach Clamp Nut 2500111722 75 102 53 Valve Cover Nut 500 1 2 60 81 Table 6 Torque Values for Critical Pump Fasteners Page 35 of 47 AM A American Mfg Company Quality Mud Pumps and Parts 12 0 Critical Clearances When maintenance requiring disassembly of the power end is performed the following clearances should be checked to see if they are within factory specification or within maximum allowable limits Additional clearance is allowed for component wear This additional clearance is a maximum of 002 inches of total diametral wear that can be added to the clearance values in Table 7 For radial clearance use of the total diametral value All dimensions are shown in inches
42. penings Remove the piston cup seals as described in Section 9 0 Service Procedures Replacing Cup Type Pistons of this manual seal them in a bag to protect against ozone and store them in a separate location with a controlled environment where they are protected from UV exposure Drain the oil from the pump power end Remove the rear Page 8o0f 47 AME A American Mfg Company Quality Mud Pumps and Parts cover to expose the drive components Spray all internal parts with a rust preservative that is soluble in lubricating oil while rotating the driveshaft several turns by hand to ensure complete coverage Replace the rear cover and add 2 to 1 cup of internal rust inhibitor described in Table 2 Spray a rust preventative onto all exterior machined surfaces paying attention to any unpainted areas like the crankshaft extension Remove the oil fill cap and store with the piston cup seals Cap the breather opening with a plug or other suitable means in order to keep the preservative atmosphere sealed inside the power end Never store the pump on the floor or ground Always place it on a shelf or pallet that is several inches above ground level Cover the entire pump with a canvas or plastic tarp Every two months inspect the unit Rotate the crankshaft by hand at least 4 turns during each inspection Drain and replace the rust inhibitor after every six 6 months of storage 3 4 Returning a Stored Pump to Operation Before operating a pump that has
43. piston assembly into the liner until NOTE The following tools are available and may be the sealing lip has just entered the front of the liner Use purchased at American Mfg Company s worldwide a small amount of glycerin on the ID of the liner to help network of distributors lubricate the piston during installation After the liner has been installed in the pump power frame drive the piston assembly fully to its stop using the American Mfg Component Description Part Company piston tool PPFMC A5049 and a rubber Tool Bearing Press For Pinion PPAM A000387000 mallet Te To fte em eel ere IN PPAM A000396000 Tool Ball Seat Driver PPAM A000398000 1 It is recommended that a sufficient quantity of EE PPAM A000239000 clean water be pumped through the fluid end before Tool For Housing Cup Press PPAM A000401000 starting any service procedures that involve fluid end components This will remove a significant portion of Tool Hand Crank Pinion PPAM A000402000 contaminants left in the fluid cylinder by the normal Tool Stud Nut PPAM A000410000 pumpage and improve the ability to work with parts es Peto Net Remaver PPFMC A5049 or see potential problems Table 5 Service Tool Item Numbers 2 Bleed off all pressure inside pump fluid end before starting any service work Shut the valve off on the inlet piping if provided to prevent flow of liquid from the source into the pump during service CAUTION
44. pry bar to ensure the crankshaft is to one side 27 Mount indicator base on the power frame with the indicator tio on a machined shoulder surface of the crankshaft do not measure from a cast surface and the axis of the indicator parallel to the crankshaft 28 Set the dial indicator to zero 29 Move the crankshaft back over to the opposite side and read the bearing end play as total indicator movement Rotate the crankshaft several turns then repeat moving the crankshaft in the direction described in this step Repeat the dial indicator measurement Remove or add shims as necessary to achieve proper endplay 002 tight to 003 loose Distribute shims equally on both bearing housings Verify the endplay with the dial indicator per this procedure described before final assembly 30 Install the piston rod seal holder 9 and seal retainer 8 in the power frame per instructions in section 10 1 The crankshaft should turn freely 31 Complete reassembly of pump Tool PPAM A000387000 can be purchased to aid in the assembly of the pinion bearing if needed 32 Torque all fasteners as outlined in Fastener Torque Requirements Section 11 0 of this manual Page 34 of 47 AM A 11 0 NOTICE No pump service procedure is complete without applying the proper fastener torque Failure to properly American Mfg Company Quality Mud Pumps and Parts Fastener lorque Requirements tighten the pump bolts could cause the pum
45. rn check valves e Excessive leakage from pump seals e Check belt tightness or power to motor e Check relief valve and adjust setting Properly service system e Inspect check valves and repair or replace e Adjust or replace packing or damaged parts Insufficient flow from pump ONLY e Pump speed is too low e Relief valve improperly adjusted or worn e Worn pump valves e Excessive leakage from pump seals e Plunger or piston worn e Valve seat washed out in fluid cylinder e Check belt tightness or power to motor e Check relief valve and adjust setting e Inspect pump valves and repair or replace e Adjust or replace packing or damaged parts e Replace plunger or piston e Repair or replace fluid cylinder Insufficient floor or pressure AND rough operation pump pounds or vibrates e All pump cylinders not primed e By pass or relief is piped back to suction e Inlet line too long or too small in diameter e Insufficient NPSHA e Air leaks in suction line or fittings Vortex in tank near inlet pipe opening e Air entering booster pump e Pump valve stuck open or closed e Valve assembly damaged or unseated e Valve seat washed out in fluid cylinder e Gas pocket formation from high spots in suction e Prime all chambers e Pipe back to reservoir tank e Increase suction pipe size e Provide more NPSH Correct installation to stop leaks e Increase submergence or baffle to stop vortex Co
46. rrect installation of booster pump e Clean and deburr valve e Properly seat or repair valve e Repair or replace fluid cylinder e Correct suction line installation Page 37 of 47 AMI American Mfg Company Quality Mud Pumps and Parts knocks or vi brates ONLY e Loose plunger piston or rod e Low oil level in power end e Excessive connecting rod brg clearance e Excessive main bearing clearance e Worn wrist pin or bearing e Pump running backward e Loose sheaves or bushings v belt drive Gear tooth cracked or broken e Insufficient NPSHA e Excessive acceleration head in suction line e Pulsation dampener improperly charged e Inlet line too long or too small in diameter e Worn piston seal allows air ingress usually observed when booster not used Symptom Possible Cause Possible Solution Pump runs e Broken or weak valve spring e Replace valve spring rough e Valve damaged or unseated Repair replace valve or re seat e Tighten loose components e Fill to proper level e Check cap torque or replace bearings e Adjust end play e Replace worn components Correct rotation e Tighten loose components e Replace gear e Provide more NPSH e Install suction stabilizer e Charge to proper pressure e Increase suction pipe size e Replace piston seal e Packing too tight e Misaligned coupling e Belts too tight e Power end bearings too tight e Low motor voltage Rapid suc
47. rts ALO9 18BCD Component ltem Numbers Table 4 Component ltem Numbers Component Component ltem Description Part Qty ltem Description Part Qty Power Frame PPFMC 5260537 1 31 Plate Inspection PPFMC 1214260 1 2 Crankshaft PPFMC 1279071 32 Pipe Plug Power End PPFMC 1187048 2 3 Pinion Shaft PPFMC 1265098 1 33 Filler Cap or Vent PPFMC A5054 1 4 Connecting Rod Assembly PPFMC 18710 3 34 Screw PPFMC 1106980 2 5 Rod Bearing PPFMC P506697 3 38 Fluid Chamber PPFMC 1255266 1 6 Wrist Pin PPFMC A5006 3 S Valve Seat PEEMG 1225327 6 f Crosshead Assembly PPFMC 1250876 3 40 Piston Cup PPFMC 5260052 3 8 Seal Holder PPFMC 1283601 3 4 Piston Holder PPFMC 8495 3 9 Oil Seal Piston Rod PPFMC 1283603 6 A2 Hex Nut PPFMC 8309 3 10 Seal Retainer Nut PPFMC 1283600 3 43 Nut Retainer PPFMC A5016 3 11 Gasket Seal Retainer PPFMC 1283602 3 44 Piston Retainer PPFMC 1207289 3 12 Bearing Housing Blind PPFMC 1279064 2 45 O Ring Rod Seal PPFMC 1101176 3 13 Shim Bearing Housing PPFMC 1252594 5 46 Gasket Fluid Chamber PPFMC 1280024 6 14 Gasket Bearing Housing PPFMC A5025 2 47 Plug Pipe De R301267 6 13 Back Cover PPFMC 1279063 48 Plug Suction PPFMC 1105105 2 16 Gasket Back Cover PPFMC 1279065 1 A9 Valve Cover PPFMC A5003 3 17 Pinion Housing Drive PPFMC A5005 50 Gasket Valve Cover PPFMC 1280026 3 18 Pinion Housing Blind PPFMC 1225769 1
48. ss it is held in position until it cools enough to grab the shaft Use a 001 thick feeler gauge to ensure the cone is fully seated against the shoulder after the parts have cooled 18 Use a press to seat the new cones 23 into the bearing housings Never use new bearing cups with old bearing cones Always use matched sets from one manufacturer 19 Reassemble the crosshead assemblies and connecting rods Ensure that the set screws 30 retaining the wrist pin 6 are in place The set screw must engage the flat on the wrist pin Refer to Section 11 0 for torque specifications 20 Push the crosshead connecting rod assemblies fully forward in power frame to provide maximum clearance for the crankshaft Ensure crosshead assemblies are replaced in the same orientation and in the same cylinder bore they were originally NOTE The oil cup pocket feeds lubricant to the wrist pin bushing This is located on the top of the connecting rod and should be in the up position 21 Install crankshaft in the power frame Take care not to scratch the bearing surfaces of the crankshaft 22 Inspect the gasket 14 that seals the bearing housing and replace if damaged Reinstall the shims 13 and bearing housings 12 As a starting point install the same number of shims that the pump originally had prior to service work When tightening the fasteners retaining the bearing cover use a crisscross pattern for tightening with a torque wrench 23 Replace the
49. ston rods during assembly 11 Tighten all fasteners to the values specified in Fastener Torque Requirements Section 11 0 of this manual Page 23 f 47 AM A American Mfg Company Quality Mud Pumps and Parts 9 Removing the Fluid Cylinder NOTE The fluid chamber 56 may be removed to inspect for internal damage to be repaired to replace the fluid cylinder to replace damaged cylinders cylinder o rings or to service piston rod seals Refer to Figure 3 for illustration of parts 1 It is recommended that a sufficient quantity of clean water be pumped through the fluid end before starting any service procedures that involve fluid end components This action will remove a significant portion of contaminants left in the fluid cylinder by the normal pumpage and improve the ability to work with parts or see potential problems 2 Bleed off all pressure inside pump fluid end before starting any service work Shut the valve on the inlet piping if provided to prevent flow of liquid from the source into the pump during service CAUTION Check to ensure that the power is locked out and tagged out 3 Remove the cylinder cover clamps 57 and cylinder covers 54 as described in the previous section Remove the outside corner fluid chamber nuts 61 if they are still in place 4 Rock the fluid cylinder fluid chamber to loosen from the cylinders liners 56 and pull free of the fluid end studs If the pistons have already been rem
50. the run blow compressed air through the fluid end to remove all traces of fluid Remove the bottom plugs and cylinder covers from the fluid cylinder Drain the liquid from the discharge valves first and then the suction valves by lifting the valves This ensures all fluid to be drained from the pumping chamber between the suction and discharge valves As an alternative to the previous procedure a compatible antifreeze solution can be circulated through the fluid end RV antifreeze propylene glycol is recommended for this purpose Remember that any fluid that poses an environmental hazard or is toxic must be handled and disposed of properly Page 9of 47 AM A American Mfg Company Quality Mud Pumps and Parts 4 0 Installation Guidelines A proper installation is essential to optimal performance long service life and reduced maintenance requirements Take time to thoroughly plan all aspects of your installation 4 1 General Location It is important to position the pump on as flat and level a surface as possible to assist the splash oil lubrication system Park mobile equipment such as sewer cleaner trucks or drilling machines on as level a surface as possible Whenever possible the pump should be mounted in a clean dry location with sufficient lighting and adequate space for easy inspection and maintenance Locate the pump as close to the suction source as possible to allow for the shortest and most direct routing of the inlet piping
51. to fail resulting in equipment damage and possibly personal injury Normal hose pressure ratings are clearly marked on the outer surface of the hose Working pressure ratings for steel pipe can be obtained from the manufacturer or from the chart shown in Table 1 Pipe Size Discharge Piping Recommendations Allowable Working Pressure For Steel Pipe PSI 100F inches 40 80 120 160 XX 1722 2 300 4 100 7 300 12 300 3 4 2 000 3 500 8 500 10 000 ZO 3 000 5 700 9 500 11 4 1 800 3 000 4 400 900 1 1 2 1 700 2 800 4 500 7 200 2 1 500 2 500 4 600 6 300 2 1 2 1 900 2 800 4 200 6 900 3 1 600 2 600 4 100 6 100 4 1 400 2 300 3 3390 4 000 5 300 5 1 300 2 090 2 950 3 850 4 780 6 T210 2 070 2 850 3 700 4 660 8 1 100 1 870 2 840 3 700 3 560 14 5PSI 1 BAR Table Pipe Pressure Chart Page 11 of 47 AMI A American Mfg Company Quality Mud Pumps and Parts 2 Always use a pressure gauge in the pump discharge line A properly functioning gauge mounted at the pump and before any valves is required to accurately determine the operating pressure of a pump and to conduct troubleshooting 3 Ensure that all piping is supported independently of the pump to reduce vibrations and strain on the pump Pulsation dampeners on the discharge are recommended to reduce pressure pulsation and resulting vibration The use of elbows nipples unions or other fittings should be kept to
52. ump design and speed and is determined by the pump manufacturer through a specific NPSH test NPSHR should exceed NPSHA by at least 5 feet Page 44 of 47 AM A American Mfg Company Quality Mud Pumps and Parts PISTON PUMP A type of power pump that uses a cylindrical seal piston mounted on a holder to drive fluid through the valves The piston seal reciprocates within a stationary cylinder PLUNGER PUMP A type of power pump that uses a cylindrical plunger to drive fluid through the valves The plunger reciprocates through a stationary set of seals known as packing POWER END The portion of the pump that converts supplied rotary motion into linear motion used by the Fluid End to move the pumpage POWER FRAME The major portion of a power pump that encloses and supports all other components of the power lor drive end It is called a pump case in old literature POWER PUMP A reciprocating pump that drives the pumping element s using a slider crank mechanism Power pumps are piston plunger or diaphragm type All require a driver with a rotating shaft such as a motor or engine as a power source PUMP VALVE A check valve that allows flow of liquid in one direction American Mfg Company pumps have a series of two valves one suction inlet and one discharge per pumping cylinder STROKE LENGTH The length of one complete unidirectional motion of the piston or plunger Stroke length is usually expressed in inches VOLUME
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