Operating Instructions

For LGF-1000 Drilling Pump

Sichuan Gaosheng Machinery Manufacturing Co., Ltd.

Tel: 028-85730676 , 028-85730698

Add.: Jiaolong Industrial Zone, Shuangliu County, Chengdu, China

CONTENTS

1. Overview

2. Technical Specifications

3. Flow Rate vs. Pressure

4. Features of Main Components

5. Assembly and Disassembly of Main Components

6. Assembly, Startup and Running Monitoring of Drilling Pump

7. Maintenance

8. Troubleshooting

9. Notes for Storage

10. Special Lubrication Oil and Grease

11. List of Supplied Special Tools

12. Recommended Order List

13. List of LGF-1000 Drilling Pump Drawings

14. List of Spare Parts

1

1. Overview

LGF-1000 drilling pump is a kind of horizontal triplex single-acting piston pump,

made up of power end and fluid end, designed with advanced structure, small size,

reliable operation mechanism, exchangeable components, and easy maintenance. The

consumables, bearings, sealing parts and technical parameters of this pump are the

same as those of F-1000 pump.

The power end includes framework, pinion shaft assembly, crank shaft assembly,

crosshead assembly and pony rod, etc. The fluid end includes module, valve assembly,

liner, piston assembly, suction manifold, etc. In order to avoid gas lock and reduce the

pressure pulsation at the discharge outlet, a suction pulsation dampener and a

discharge pulsation dampener are installed respectively at the suction pipe and the

pump outlet. And a shear-pin safety valve is installed at the other end of the pump

outlet to ensure the pump pressure not to exceed the rated working pressure.

Splash lubrication and forced lubrication are combined for the gears, bearings and

crosshead at the power end to ensure sufficient lubrication, while the water supplied

by spray pump is used to lubricate, clean and cool the liner and piston at the fluid end.

A special set of handling (assembly and disassembly) tools are provided for routine

maintenance of the drilling pump.

When LGF-1000 drilling pump remains in good condition it will be an excellent

partner of every drilling worker and bring you great benefits.

2

2. Technical Specifications

No. Description Parameters

1 Type Horizontal, triplex single-acting piston

pump

2 Rated input power (HP) 735KW(1000HP)

3 Rated strokes 140

4 Stroke length 254 mm (10in.)

5 Gear type Herringbone tooth

6 Gear ratio 4.207:1(122:29)

7 Suction connection size 12” flange

8 Discharge connection size 5-1/8”flange 5000#API

9 Pinion shaft diameter and

extension (mm/in.) 196.85/7-3/4 ×336.55/13-1/4”

10 Key connection size (mm/in.) 50.8×50.8 / 2”×2”

11 Module API 6#142.875/5-5/8”

mm 4269×3167×1818 12 Dimensions

in. 168”×124-5/8”×71-1/16”

13 Base width (mm/in.) 1790/70 1/2”

14 Pump weight (kg/lb) 18790/41420

3. Flow Rate vs. Pressure

Liner ID (in) 6 3/4″ 6 1/2″ 6 1/4″ 6″ 5 1/2″ 5″ 4 1/2″

Rated WP (MPa） 16.4 17.6 19.1 20.7 24.6 29.8 34.5

Strokes per Power（HP） Flow Rate (L/s)

3

Minute

（spm）

KW HP

140 735 1000 41 38 35.2 32.4 27.2 22.5 18.2

130 683 929 38.07 35.28 32.68 30.1 25.26 20.89 16.9

120 630 857 35.14 32.57 27.86 27.77 23.3 19.28 15.6

110 578 786 32.21 29.85 27.66 25.46 21.37 17.68 14.3

100 525 714 29.28 27.14 25.14 23.14 19.43 16.07 13

1 5.25 7.14 0.293 0.271 0.251 0.231 0.194 0.161 0.130

Assuming the mechanical efficiency η =90%,fill factor α =100%, and volumetric

efficiency=100%.

4. Features of Main Components

LGF-1000 pump consists of 2 parts, power end and fluid end. The power end is used

to provide adequate power to the fluid end, and the fluid end is used to convert the

mechanic energy to the internal energy of the fluid to convey drilling mud. The

combination connection of framework, base support, cylinder, suction pipe and

discharge pipe forms the whole set, characteristic of small in size, high in strength,

and compact in structure. Please refer to Fig. 1.

4

Pinion Shaft Assembly Discharge

Pipe Fluid End Assembly

Crosshead AssembliesCrankshaft

Assembly Framework Assembly

Fig.1 Structural Schematics of LGF-1000 Drilling Pump

1) Power End

The power end includes framework, pinion shaft assembly, crank shaft assemb

crosshead assembly.

a. Framework

The framework is the base of the LGF-1000 pump, all pump components are i

on the framework. It is welded in the form with steel plates. And stresses hav

treated already, with high rigidity and high strength. All necessary oil pools

passages are designed in the framework, used for lubrication and cooling.

b. Pinion Shaft Assembly

The pinion shaft is made of forged alloy, with herringbone teeth and mediu

tooth surface. It turns smoothly and has a high efficiency and a long servi

Roller bearings are placed at the journal area without retaining edge at the inn

so as to facilitate the repair check. Both ends of the shaft extend out, belt w

chain wheel can be mounted at either end, with the other end installed with

sheave which drives spray pump or charge pump.

c. Crank Shaft Assembly

The bull gear, connecting rod and bearings can be installed respectively

crankshaft.

The bull gear will engage with the gears on the pinion shaft. A tight fit exists b

SuctionPipe

ly, and

nstalled

e been

and oil

m-hard

ce life.

er race,

heel or

pulley

on the

etween

5

the inside of the bull gear and the crank shaft, with 12 bolts to connect and locknuts to

tighten.

d. Crosshead Assembly

The coaxiality between the crosshead and the guide can be adjusted by inserting

spacers at the lower guide.

The crosshead and the connecting rod are connected by rabbet locating bolts, to

ensure the two aligned axially. The bolts are tightened according to required torque

value, and locking wires used.

A crosshead pin is used at the middle of the crosshead to connect with the small end

of the connecting end. For easy assembly and disassembly, a tapered fit is used

between the crosshead and the pin, with a clamp plate pressed tightly the crosshead at

the big end, and bolts tightened with the torque required, and locked by wires.

2) Fluid End

The fluid end includes 3 exchangeable modules. A set of suction valves and discharge

valves are mounted inside each module.

DischargePipe

Safety Valve

Dampener

Pr e

The 3 modules are secur

above the cylinder, with

one side, while an elbow

valve and anti-shock p

Anti-shock essure Gaug

Fig. 2

ed on

disch

pipe

ressur

Discharge FilterHolder

A

Structure of Discharge Manifold

the framework by bolts. Discharge manifold is instal

arge outlets at both sides. And a filter can be installed

installed at the other side. Pulsation dampener, saf

e gauge can be installed on the elbow pipe. For

Elbow

Cylinderssembly

led

at

ety

the

6

structure of the discharge manifold, please refer to Fig. 2.

a. Module

Straight-way type module is adopted, made of forged steel alloy. The fluid flow rates

in all the modules are the same, preventing the valve assembly from the influence of

the cross flows discharged out of other modules. The valve sizes conform to the API

standards.

b. Liner, Piston, and Clamp

Bi-metal quality liner is used. The inner is made of wearable forged steel, hardness up

to HBC 60-65, and the ID surface has high fineness. The liner is variable in several in

ID sizes, and the same as the sizes of the piston matching with the liner. Liners and

pistons of different ID’s are used for different drilling conditions.

The piston is consisted of piston core, rubber cup, clamp plate, and snap spring. The

piston and piston rod have a cylindrical surface fit, sealed by seal parts, and lock nuts

with lock rings used to press tight, which can not only lock the nut after tightening but

also seal there between.

The piston rod and the pony rod are connected by clamps, has rabbet locating device

at the juncture to ensure the axiality.

c. Cylinder lid, cylinder lid plug, and cylinder lid flange

The cylinder lid flange connects with the cylinder by studs, with the cylinder lid by

saw tooth threads. Press inside the cylinder lid plug, which has a central screw hole

used to install pull bar to dismount the cylinder lid plug.

d. Valve Assembly

The suction valve and the discharge valve are exchangeable. The external conical

surface with a 1:6 taper engages with the internal conical surface of the cylinder valve

seat. The sizes are as required by API 6.

3). Suction Pulsation Dampener and Discharge Pulsation Dampener

a. Suction Pulsation Dampener

The suction pulsation dampener is installed at the side of the suction manifold, to

dampen the suction pulsation to improve the volumetric efficiency.

7

b. Discharge Pulsation Dampener

Installed at the discharge elbow pipe, see Fig. 2, consisting of housing, bladder, press

board and throat flange.

The volume and the pressure load capability meet the drilling pump requirements.

Nitrogen or air can be charged inside the air dampener, but not combustible gases like

oxygen or hydrogen.

The maximum precharge pressure of the pulsation dampener is 4.5 MPa (650psi). The

stop valve will be closed after charging, to protect the pressure gauge.

c. Shear-pin Safety Valve

The shear-pin safety valve is installed at one side of the elbow pipe of the discharge

manifold, see Fig. 2, to vent quickly once the pump pressure exceeds the

predetermined value, so as to ensure the safety of the equipment. Levels of pressures

are marked on the shear plate; the pressure is adjusted by inserting the safety pin in

different holes. Take care that only 1 pin can be inserted on the pin plate. And this

valve must be installed before the stop valve, to prevent the pump from startup before

the stop valve opened.

4). Spray Pump Assembly

The assembly includes spray pump, water tank, and spray pipe, used to cool and

lubricate the liner and piston during the pump running, increase the working life of

liner and piston.

The spray pump is a centrifugal pump, driven by the driving shaft through belt wheel

(or driven by the motor separately). The water is used as the cooling and lubrication

fluid.

The spray pipe can be mounted on the clamp which connects the pony rod and the

piston rod. It can reciprocate with the piston, or fixed at a proper location, to ensure

the cooling & lubrication fluid always flush the interface of the piston and liner.

5). Charging System

This charging system can be configured as necessary, including charging pump,

support base, butterfly valve and manifold. It is driven by a motor, installed at a

8

proper place according to actual situations, normally close to the outlet at the side of

the mud tank.

5. Assembly and Disassembly of Main Components

1) Disassembly of Main Components of Fluid End

a. Disassembly of Piston

Put a round bar into the hole of the cylinder lid, to remove the lid. Then take off the

cylinder lid plug, pull out suction valve guide, and remove the clamp connecting the

piston rod and the pony rod. And rotate the pump to separate the pony rod and the

piston rod. And another bar is forced between the pony rod and the piston rod, and the

piston can be pushed out of the liner by turning the pump. The piston then can be

taken out of the liner bore of the cylinder.

b. Disassembly of Liner and Piston

First remove the cylinder lid, lid plug, suction valve, guide and the clamp connecting

the piston rod and the pony rod as described above, and then remove the cylinder liner

cover plate, and separate the piston rod and pony rod by turning the pump. And then

use a copper bar to knock evenly the peripheral edge of the liner to separate the liner

from the liner seat, and the liner and piston can be then taken out of the cylinder lid

hole at the front of the cylinder.

c. Disassembly of Upper Valve Seat

Plug a round bar into the valve pot cover hole to remove the valve pot cover, then take

out the valve spring and the valve assembly. And then use the hydraulic handling tool

provided along to remove the upper valve seat.

d. Disassembly of Lower Valve Seat

After the upper valve seat removed as above, use the special valve-seat handling tool

to take the lower valve seat out of the cylinder lid hole.

2) Assembly of Main Components of Fluid End

a. Installation of Module

Lift the 3 modules onto the framework, and secure with bolts (not too tight). The

modules should keep upright and balanced with each other. Then install the suction

9

manifold and discharge manifold. After all adjusted well, use the torque spanner to

tighten the connection bolts of the suction pipe, discharge pipe and framework to the

module to the required torque value. Note Letai gel shall be applied to the bolts and

nuts before tightening. The tightening torques for the bolts are as following.

LGF-1000

Thread size Toque (N.m)

Connection with suction pipe 7/8-9UNC-2A 298-338

Connection with discharge pipe 1-1.4-8UN-2B 1287-1355

Connection with the framework 1-1/2-8UN-2B 2134-2202

Connection with cylinder lid flange 1-3/8-8UN-2B 1775-1842

Cylinder Model

Pump

b. Installation of Valve, Valve Seat and Valve Pot Cover

Assemble the valve body, valve rubber, and valve nut together. Clean the external

conical surface of the valve seat, and make sure no nick or burrs. Then put the valve

seat inside the conical hole of the valve pot which is also cleaned already (Note: It is

prohibited to apply oil on the external conical surface of the valve seat and the

internal conical surface of the valve seat bore.). When assembling the valve seat, it’s

preferable to put an old valve body on the seat and use the iron bar to hammer 3 times

and later take away the old valve seat to check whether the valve seat is secured or not.

If no old valve body available, a copper bar can be used to knock around the upper

edge of the valve seat to seek a tight fit with the cylinder. Note the lower valve seat

should be installed before the upper valve seat.

Then mount the valve assembly onto the valve seat, with the valve spring at the center

of the valve body. The suction valve shall be installed after the liner and piston being

installed.

Grease the seal ring of the valve pot cover, and install it on the cleaned cylinder

shoulder. After the valve pot cover, valve stem guide and the baffle are installed,

apply lubrication oil on the threads of the valve pot cover and tighten with a round

bar.

c. Assembly of Piston and Liner

10

When assembling the piston, pay attention to put in O rings between the piston and

the piston rod. Otherwise the drilling mud will damage the piston and piston rod.

Then can the piston be mounted and piston nuts tightened. The torque value for

1-1/2-OUN-2B nuts is 1625-2165.

The piston can be put inside the liner after the liner be mounted on the pump body, or

it can be assembled with the liner outside the pump first, and later installed into the

cylinder together. The assembly procedure is in reverse to the disassembly procedure.

When assembling the piston into the liner, calcium grease must be precoated on the

inner surface of the liner and the external surface of the piston. Then the liner seal

rings, liner locating tool can be installed. And then the suction valve body, valve

spring, valve guide and clips will be installed. And finally the cylinder plug be

installed and cylinder lid tightened, and the clamp connecting the piston rod and the

pony rod is installed.

3) Disassembly of Main Components of Power End

a. Disassembly of Crankshaft

Take off the clamp, together with the pony rod and its packing box.

Remove the left and right crosshead pins, and then the pin at the center of the

crosshead (or remove the press board of the central crosshead pin and then

dismount the crosshead and the crank shaft together,).

Take off the left and right main bearing caps and the cap at the back. And take off

the cap of the main bearing seat. Then the crankshaft can be lifted up with a crane.

And the other parts can be disassembled as required.

b. Disassembly of Pinion Shaft

Take off the bearing caps at both ends of the framework, remove the main bearing

sleeve bolts at either end of the pinion shaft, and take the pinion shaft and the

bearing sleeve at the end without bolts out of the bore. The inner race of the

bearing is detachable.

If the pinion shaft to be dismounted without the need to disassemble the

crankshaft assembly, first support the 2 ends of the crankshaft, pull out the

bearing sleeve, making the pinion gear separate from the bull gear, and then pull

11

the pinion gear out of the framework.

If damaged bearings are to be taken out without the need to disassemble the

pinion shaft from the framework. The bearing sleeve shall be pulled out, and then

the inner race of the bearing is pulled out along the pinion shaft.

4) Assembly of Main Components of Power End

a. Assembly of Pinion Shaft Assembly (see Fig. 3)

Pinion amay be comp

Note: Be

of c Wh

dow Tig

② Assembl

Main Bear

End Cap

Fig.3nd shaft belongleted after mou

sure that the paap are positioneen mounting bnward and tow

hten the bolts ony of Crankshaf

Main Bearing

ing Cover

Bearings P

Structure of Pin to an integral mnting bearings a

cking ring of pd correctly.

earing sleeve anard discharge ho bearing sleevet Assembly(see

Crosshead Bear

Pony Rod

inion Shaft

ion Shaft Assemblyachine componen

nd spacer rings of

inion bearing slee

d cap, the oil grle.

with torque 190~ Fig. 4) ing

Bull gear

Eccentr

Bearing Housing

t. Therefore assembling oil sealings.

ve and the packing ring

ooves on them must be

255 N⋅m.

ic Cam Bearing

Bearing Housing

12

Fig. 4 Schematics of Crankshaft Assembly Assembly of bull gear:

Put bull gear on crankshaft flange. Thoroughly clean the match surfaces of the bull gear and the crank-shaft flange. Then secure the bull gear, tightening all bolts with torque 1055 N⋅m.

Mount outer races and outer retaining rings of the connecting rod bearings on three connecting rods separately. Draw-off tray must be located just under the working connecting rod. Tighten bolts of the bearing retaining ring with torque 60-90 N⋅m and lock them with wires.

When assembling connecting rods, the middle one must be installed at first, and locating ring be mounted.

When assembling lateral connecting rods, bolts on the inner retaining rings must be tightened with torque 60-90 N⋅m.

Mount the crankshaft assembly onto the framework. Before lifting the crankshaft, put wooden supporting block on each of the guides (see Fig.5).

C

Cushio

Fig

Lift the crankshaft acrosshead already mounNote that the oil catchmupward. The retainer plmiddle one be installed a

There are 2 method

Calculation me Measure th Measure th

directly fro The actu

=0.25-[0.10 Tighten the

11923N.m.

Uonnecting Rod

n Plate Lower Slide

. 5 Schematics of Wooden Su

nd put it into the framewted there. The torque value ent ditches of the retainer pates at 2 sides should be ccording to the location ofs to adjust the clearance of

thod: e outside diameter of the me diameter of the inner borm the end face of the bearinal thickness required-(A-B)]mm; main bearing bolts, 2-1

pper Slide

C

pporting B

ork, and of 6 1" -8lates of t

installed the crossh the main

ain bearine of the mg seat on of

/2-8UN-2

rosshead

lock

then connect it with the UN bolts is 225-240N⋅m. he crosshead should face at the outside, while the ead pin.

bearing.

g housing, A; ain bearing seat (or read

the framework ); the support block

A bolts, by a torque of

13

Test and adjustment method: Insert 0.50mm steel spacer at the binding face of the main bearing

cover; Put a lead wire at the middle part of the engagement area between the

inside bearing cover hole and the bearing. Tighten the main bearing cover bolts with required torque value; Remove the bearing cover, and measure the thickness of the lead wire; The pre-compression of the bearing cover is 0.10mm; The actual thickness required of the spacer =0.50mm (thickness of the

adjustment spacer)-the thickness of the compressed lead wire – 0.10mm (pre-compression of the bearing).

−

Main BearingMain Bearing Bolt

Main Bearing HousingLead Wire

6. Pump St

1) Installatio

a. The mud p

tilted to the fl

b. The mud p

should be pla

pump.

c. The suctio

tank bottom,

suction pipe s

d. Secure all

Be

a

n

u

u

u

c

n

a

h

s

aring Cover

Shim

Fig. 6 A

rtup after In

mp should be in

id end (at an inc

mp should be in

ed as high as p

end of the pum

nd the ID of the

all not face the i

uction and disc

djustment of Main Bearing C

stallation and Runnin

stalled on a foundation h

lination ≤3º), to ease the f

stalled at a level as low as

ossible, to improve the s

p suction pipe should be

suction pipe must be co

nlet of the mud tank.

harge pipelines, to prev

lear

g M

oriz

low

po

ucti

300

nsta

ent

C

ance

on

ontal

of th

ssible

on ef

mm

nt, th

unne

rank Shaft

itoring

ly placed or slightly

e lubrication oil.

, while the mud tank

ficiency of the mud

higher than the mud

e suction end of the

cessary stresses and

14

minimize vibration. The pipelines are prohibited to hang around the pump without

firm support.

1) Pump Startup

a. Preparation before startup

Check the bottom of the framework of the power end. Discharge all lubrication

oil if any and clean the oil tank. If the oil has been discharged already, check to

see if the tank is clean. Then feed lubrication oil to the maximum level. The

lubrication oil used is as following.

Season Summer Winter

Lube N320 moderate-extreme pressure

gear oil (S-P type ) plus 10%

4#antirust compound, or 200#

moderate-extreme pressure gear

oil (S-P type ) plus 10%

4#antirust compound

N220 moderate-extreme pressure

gear oil (S-P type ) plus 10%

4#antirust compound, or 120#

moderate-extreme pressure gear

oil (S-P type ) plus 10% 4#antirust

compound

Open the upper peephole cap of the mud pump, feed sufficient lubrication oil into the

oil ditches of the pinion bearing and the crosshead, keeping all friction faces of the

pump lubricated before startup.

Check the crosshead clearance. The clearance between the upper crosshead

surface and the slide shall not be less than 0.5mm (0.02in.). The clearance of the

crosshead can be larger. This is because the working properties of the triplex

pump. The load of the crosshead is always exerted on the lower slide during

forward running of the pump. While during reverse running, the load of the

crosshead is exerted on the lower slide. So the clearance of the slides must be

controlled between 0.45～0.55mm (0.0177～0.0217in.).

Check the cooling lubrication oil in the oil tank of the spraying pump to see if it

meets the requirements.

Tighten all bolts. Check the valve pot cover and cylinder lid to see if they are

tightened enough. And check the bolts of the connecting clamp of the piston rod

15

and the pony rod are tightened or not. Take out the supporting block at the

crosshead hole to see any unnecessary objects inside the pump or the framework.

Check all valves on the mud lines to see if they are properly opened or closed as

required before the startup.

Check the charging pressure of the discharge air dampener, if reaching 4.5MPa.

Open the suction and discharge valves of the spray pump system and the charging

system (if necessary).

Check the discharge safety valves and the pressure gauges to see if they are

equipped complete and sensitive.

Fill the suction valve pots with water or mud to vent out all air.

b. Startup

Start at a speed as low as possible, and then speed up gradually, so as to improve

volumetric efficiency.

When the charging pump is not used, lower the maximum speed of the pump to a

value which can keep the pump work normally. If the pump speed needs to be

quickened, the charging pump must be used.

Check the readings on the pressure gauges along the lubrication oil loop. If no

readings, repair in time.

Check temperatures all around, no local overheating is permitted.

Operator and inspector should be contacted before pump startup.

The inspector must watch the pressure readings on the gauges when the pump is

started. The workers cannot leave the air switches before the mud returns to the

surface.

When engaging the clutch, 2-time startup method is adopted, which can give a

chance for the pump to move, and also can observe if any obstacles exist during

pump startup. If all normal, engage the clutch.

c. Monitoring the Pump Running

Check to see any abnormal noise in the clamp connecting the piston rod and the

pony rod. Check all screw caps on the cylinder and all valve pot cover to see if

they are loose or not. Any anomalies found, find the reasons and solve them in

16

time.

Check to see any leakage at high pressure sealing points, any spur leakage at

pump valves or cylinder, if any problems found, solve in time.

Note variations of pump pressure, solve properly if any anomaly found.

Check to see if the water/oil supply to the spray pump normal or not.

Check if the temperatures is too high or not at all bearings, crosshead slides and

other moving parts.

Check to see if the pressure gauges on the lubrication oil loop of the power end

behind the framework work normally or not.

7. Pump Maintenance

Proper and timely maintenance of mud pump is necessary to ensure normal work and

a long working life of the pump. Attention should be paid to every pump in this

respect when it is in operation.

1). Daily Maintenance

a. Check the oil level of the power end after the pump shut down. If it is chain driven,

the oil level in the chain box should also be checked.

b. Check the running condition of the liner and the piston. It’s normal if small

amounts of mud leaks, the pump can continue working. If the leakage exceeds the

limit, the liner and the piston must be changed.

c. Check the liner bore of the framework. If there is large mud precipitation, clean it.

d. Check if there is sufficient cooling lubrication oil inside the oil tank of the spray

pump. If the oil has been contaminated, replace the oil, the same time the oil tank

must be cleaned.

e. Check the charging pressure of the discharge pulsation dampener to see if it meets

the operating requirements.

f. Regularly check the reliability of the safety valves.

g. Loosen the connecting clamp daily, turn the piston 1/4 round, and then retighten the

clamp again. This will make the piston surface worn evenly, so as to elongate the life

of the piston and the liner.

17

h. Before tightening the cylinder lid and the valve pot cover, apply lubrication grease

to the threads. And check every 4 hours to see if they are loose or not.

2) Weekly Maintenance

a. Dismount the valve pot cover and the cylinder lid once a week, remove the sludge

and clean, and apply supramoly calcium-base compound lubrication grease. Check the

inner sleeve of the valve guide sleeve, if it is worn too much (the clearance between

the valve guide stem and the guide sleeve exceeds 3mm), replace it.

b. Check the condition of the valves and the valve seats. Replace the seriously worn

or pierced valve seats, valve rubber elements and valve seats (the valve bodies will be

replaced together when the valve seats are replaced.).

c. Check the piston-locking nuts. Replace if they are corroded or damaged (Normally,

the seal rings inside the nuts will not lock any more if having been tightened 3 times.).

d. Drain off the water through the plug at the drainer cap once a week, till oil comes

out.

3) Monthly Maintenance

a. Check all studs and nuts at the fluid end. Such as nuts on the flange of the cylinder

lid, nuts used to connect cylinder and the framework, and the bolts and nuts

connecting the suction pipelines and discharge pipelines. They must be retightened

with required torques if found loose.

b. Check the seal rings inside the packing box of the pony rod. Replace if found worn.

However, they must be replaced once every 3 months at least. Please pay attention to

the directions of the oil seals when replacing. See Fig. 7.

18

S

Upper Slide

Fig. 7 Schematics of

c. Dismount the filter inside the discharge m

d. Replace the dirty oil in the oil reservoir

ditch of the crosshead once every 6 months

4). Yearly Maintenance

a. Check to see if the crosshead slides got

the crosshead complies with the requirem

spacers under the slides). The crosshead c

the crankshaft assembly.

b. It is recommended to make an overall ch

whether or not the main bearings, connec

and driving shaft bearings are worn or d

unable to be used any more.

c. Check the gears. Reassemble both the d

way if it is found seriously worn, use the un

5) Other Maintenance Concerns

a. Clean the 25°conical surface before mo

and the piston rod.

b. The liner seals must be replaced together

c. Drain all the mud inside the valve pot

winters.

d. All the check holes or windows of the

ingle-lip Oil Seal

D

Crossh

Assembly of Oil Seals

anifold and clean it

at the power end an

, and flush the oil dit

loose or not, if the

ents or not (can b

an be rotated by 18

eck of the pump eve

ting rod bearings, c

amaged. Replace ne

riving shaft and the

worn gear surfaces.

unting the clamp co

with the liner.

and the liner after th

pump must be cov

ouble-lip Oil Seal

ead pony rod

.

d in the oil deposition

ches.

operation clearance of

e adjusted by adding

0°when disassembling

ry 2 or 3 years. Check

rosshead pin bearings,

w ones if it is found

driven shaft the other

nnecting the pony rod

e pump shut down in

ered to prevent dirt or

19

sands from mixing with the lubrication oil.

e. Only inert gases like nitrogen can be charged in the discharge pulsation dampener.

Combustible or explosive gases like oxygen or hydrogen must be inhibited.

8. Troubleshooting

1) Fluid End

Problems Causes Solution

1. Readings on the pressure gauge drop. The displacement volume reduces or no displacement.

1. Air got inside the pump due to the inefficient sealing at the suction pipe. 2. The suction filter is completely blocked.

1. Tighten the flange bolts of the suction pipe or replace the gaskets. 2. Shut down the pump, and then pull up the suction pipe to clean the filter.

2. The fluid discharge is unsteady, with fluid surges. The readings on the pressure gauge vary a lot. The suction pipe makes loud noises.

1. One piston or one valve is seriously damaged or worn. 2. Air got inside the pump cylinder.

1. Replace the damaged piston: open the valve pot cover to check if it is damaged or stuck. 2. Check to see if the suction pipe and the valve pot cover have a good seal.

3. Violent knocking sounds heard out of the liner.

1. The piston nut got loose. 2. The cylinder lid got loose.

1. Tighten the piston nut. 2. Tighten the cylinder lid.

4. Mud leakage found out of the valve pot.

1. The valve pot cover not tightened enough. 2. The seal rings are damaged.

1. Tighten the valve pot cover. 2. Replace the seal rings.

5. The discharge pulsation dampener cannot be charged with gas or the gas leaks out soon after it is charged.

1. The gas charging joint is plugged. 2. The bladder in the dampener is broken. 3. The needle valve is not well sealed.

1. Clean the charging joint. 2. Replace the rubber bladder. 3. Repair or replace the needle valve.

6. Too much load on the diesel engine.

1. The discharge filter is plugged.

Disassemble the filter, clean away the impurities and flush clean.

2) Power End

Problems Causes Solutions

1. High temperature at 1. Oil pipe or oil holes are 1. Flush the oil pipe and

20

the bearings. plugged. 2. Lubrication oil is dirty. 3. Rolling bearings are worn or damaged.

oil holes. 2. Replace new clean oil. 3. Disassemble the bearings, seek causes and replace if necessary.

2 ． Knocking sounds

come from the power end.

1. The crosshead or the guides are damaged. 2. The crosshead bearings are worn. 3. The driving shaft bearings, driven shaft bearings or the bearings at the big end of the connecting rod are worn.

1. Adjust the clearance or replace the worn guides. 2. Replace the crosshead bearings. 3. Replace the bearings.

9. Notes for Storage

1) The mud pump must be sealed up for storage if it will not be used for a long time.

2) Before the storage, the pump must be cleaned thoroughly without any dirty

material remaining. Drain, flush and dry up all parts of the fluid end.

3) Drain the machine oil at the bottom of the gear case at the power end, and clean the

bottom.

4) Viscous oil shall be applied to the machining surfaces of bearings, crosshead, gears,

piston rod, and pony rod.

5) Grease shall be applied to the machining surfaces of all parts of the fluid end.

6) The suction and discharge ends shall be covered with blank plates.

7) The end cap, back cap and peephole cap of the crosshead should be tightly covered.

10. Lubrication Oil and Lubrication Grease for the Pump

1) For lubrication of gears, bearings, and crosshead

In winter, 22# hyperbola gear oil (code: HL57-22), or N220 moderate-extreme

pressure gear oil (S-P type) plus 10% 4# antirust compound.

In summer, 28# hyperbola gear oil (code: HL57-28), or N320 moderate-extreme

pressure gear oil (S-P type) plus 10% 4# antirust compound.

2) For lubrication and cooling of liner and piston, fresh water is used.

3) Supramoly calcium-base compound grease is used for lubrication of threads.

4). Calcium-base grease is used for piston and liner.

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11. List of Supplied Special Tools

NO. Drawing No. Descriptions Material

Qty. Unit weight

Total weight

Note

1 LGF3101-25.01 Sleeve 2″ 35CrMo 1 1.34 1.34

2 LGF3101-25.02 Sleeve 2-3/16″ 35CrMo 1 1.5 1.5

3 LGF3101-25.03 Sleeve 2-3/8″ 35CrMo 1 1.7 1.7

4 LGF3101-25.04 Sleeve 3-3/8″ 35CrMo 1 2.0 2.0

5 LGF3101-25.05 Joint 1″ 35CrMo 1 0.38 0.38

6 LGF3101-25.06 Extension bar 8″ 35CrMo 1 1.6 1.6

7 LGF3101-25.07 Extension bar 24

″

35CrMo 1 2.35 2.35

8 LGF3101-25.08.00

Liner plug puller welded 1 2.5 2.5

9 LGF3101-25.09.00

Valve stem guide handling tool

welded 1 0.81 0.81

10 LGF3101-25.10.00

Liner retainer puller

welded 1 2.7 2.7

11 LGF3101-25.11.00

Hydraulic valve puller

welded 1 73.4 73.4

12 LGF3101-25.12 Transition taper sleeve

35CrMo 1 1.21 1.21

13 LGF3101-25.13 Compression sleeve

35CrMo 1 2.74 2.74

14 LGF3101-25.14 Sleeve 1-1/2″ 35CrMo 1 0.85 0.85

15 LGF3101-25.15 Sleeve 1-5/8″ 35CrMo 1 0.95 0.95

16 LGF3101-25.16.00

Long sleeve

1-5/16″

Q235A 1 7.45 7.45

12. Recommended Order List

No. Drawing No. Descriptions Qty. Note

22

1 LGF3101-05.17.00 Valve assembly (API 6#)

6

2 LGF3101-05.17.05 Valve rubber (API 6#) 6 3 LGF3101-25.22A

Liner 6-1/2″ 3 common

LGF3101-25.22A Common 4 LGF3101-25.22 Liner 6-1/4″ 3

Bi-metal LGF3101-25.22A Common 5 LGF3101-25.22 Liner 6″ 3

Bi-metal LGF3101-25.22A Common 6 LGF3101-25.22 Liner 5-1/2″ 3

Bi-metal LGF3101-25.22A Common 7 LGF3101-25.22 Liner 5″ 3

Bi-metal 8 LGF3101-05.22.19.06.00 Piston 6-1/2″and

rubber 3

9 LGF3101-05.22.19.05.00 Piston 6-1/4″and rubber

3

10 LGF3101-05.22.19.04.00 Piston 6″and rubber 3 11 LGF3101-05.22.19.03.00 Piston 5-1/2″and

rubber 3

12 LGF3101-05.22.19.02.00 Piston 5″and rubber 3 13 LGF3101-05.21 Piston rod 3 14 LGF3101-04.09 Pony rod 3 15 LGF3101-05.18.00 Piston nut 6 16 LGF3101-05.04 Liner seals 12 17 LGF3101-05.09 Valve pot cover seals 6 18 LGF3101-05.20 Piston seals 6 For piston 19 LGF3101-04.18 Double-lip oil seal

4.5″×5.5″×0.5″ 6 For pony rod

20 LGF3101-27.03.00 Air bladder 1 For KB-75 air dampener

21 LGF3101-28.11 Shear pin 12 For shear pin safety valve

22 LGF3101-28.03.00 Piston assembly 2 For shear pin safety valve

Note: For every set of LGF-1000 mud pump delivered, 3 sets of 6-1/2″ liners and

pistons are provided.

13. List of LGF-1000 Drilling Pump Drawings Provided

No. Drawing No. Descriptions Copies Page Notes

1 LGF3101-00 LGF-1000 drilling pump

1 4 Assembly chart

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2 LGF3101-05.00 Fluid end assembly 1 2 Assembly chart

3 LGF3101-27.00 KB-75 pulsation dampener

1 1 Assembly chart

4 LGF3101-28.00 JA-3 shear pin safety valve

1 1 Assembly chart

14. List of Spare Parts

No. Part No. Descriptions Qty. Unit weight

Total weight

1 GB/T3452.1-1992 O seal ring Ф175×Ф3.55

3

2 GB/T3452.1-1992 O seal ring Ф140×Ф7

3

3 GB/T3452.1-1992 O seal ring Ф97.5×Ф3.55

3

4 GB/T3452.1-1992 O seal ring Ф185×Ф7

3

5 GB/T3452.1-1992 O seal ring Ф345×Ф7

3

6 GB/T3452.1-1992 O seal ring Ф115×Ф5.3

3

7 GB/T3452.1-1992 O seal ring Ф165×Ф7.0

1

8 LGF3101-03.08 Oil seal 8.5″×10.5″×0.625″

2 0.6 1.2

9 LGF3101-04.06 Oil seal ring 3 0.1 0.3 10 LGF3101-04.18 Double-lip oil seal

4.5″×5.5″×0. 5″ 6 0.1 0.6

11 LGF3101-05.04 Liner seals 6 0.32 1.92 12 LGF3101-05.09 Valve pot cover

seals 3 0.1 0.3

13 LGF3101-05.17.05 Valve rubber (API 6#)

6 0.25 1.5

14 LGF3101-05.19.06.02.00 Piston rubber 6-1/2″

3 1 3

15 LGF3101-05.20 Piston seals 3 0.001 0.003 16 LGF3101-05.29.01 Air bladder

(suction ) 1 4 4

17 LGF3101-09 Seal gasket (back cover watch hole)

2 0.15 0.3

18 LGF3101-22.06 Gasket ring R27 2 0.45 0.9 19 LGF3101-23 Gasket ring R44 3 0.8 2.4

24

20 LGF3101-27.01 Gasket ring R39 1 0.65 0.65 21 LGF3101-27.03.00 Air bladder

(discharge) 1 11 11

22 LGF3101-28.03.00 Piston assembly 1 0.057 0.057 23 LGF3101-28.06 Cushion gasket 1 0.1 0.1 24 LGF3101-28.11 Shear pin 10 0.022 0.22

25