F-1600HL Drilling Pump

Operation & Maintenance Manual

AH160201-00SM

CNPC Baoji Oilfield Machinery Co., Ltd.

 Safety Rules
—— Requirements of Health, Safety and Environment (HSE)
Normally, the drilling pump is installed in the environment of the oil drilling rig and such
environment has certain danger for operation of the drilling pump. Correct operation and
maintenance are very important for the reliable operation of the drilling pump.

1 Basic Safety Requirements

Although the representative of the drilling pump manufacturer may be available at site, it
will not represent that the operator of the drilling pump can be exempted from the
responsibilities of installation, operation and maintenance according to requirements of this
operation manual.
Warning: Before performing the operations of the drilling pump such as the installation,
operation, maintenance, repair and so on, please carefully read the following instructions to
avoid the accident or the damage to the equipment.
 While the drilling pump is in operation, it is strictly forbidden to perform the
maintenance and repair. While performing the installation, operation, maintenance
or repair for the drilling pump, ensure the drilling pump is at stationary state.
 The operator must wear the personnel protective equipment in complete according
to the specification.

2 Parts Replacement
While assembling or disassembling the drilling pump, the parts involved shall be
properly marked and numbered so that they will not be incorrectly installed during the
assembly. Please use the parts of good quality or manufactured by the original manufacturer
(BOMCO), otherwise it may result in the accident such as the damage to equipment or the
personal injury.

3 Maintenance
The periodical routine maintenance shall be performed for the drilling pump, otherwise it
may result in the accident such as the damage to the equipment or the personal injury.
4 Hazard Identification and Risk Control
4.1 Environmental Pollution
a) Oil seeping and oil leakage may appear at the sealing parts of drill pump power end
and rear cover, extension part of pump input shaft and pony rod sealing part etc. which may
pollute the environment. It is required to ensure that Seals at all parts is reliable in using, and
it is required to inspect and maintain at regular interval.
b) For chain drive pump unit, oil seeping and oil leakage may appear at the contact
surfaces of chain box cover and chain box body which may pollute the environment. It is
required to ensure that ventilation cap is without plugging and seals at contact surfaces are
reliable in using, and it is required to inspect and maintain at regular interval.
c) When the valve assembly or piston of cylinder liner is replaced, the effluent could
drop on the ground or flow into ocean. Therefore, the effluent collector shall be provided and
regularly cleared.
4.2 Personal Injury
a) Relief line of relief valve could get loose or fly off when it is relieving, which may
cause the mechanical accident and /or casualty accident. The following requirements for
installation shall be followed:
 Relief line shall keep a downward dip angle from the horizontal direction;
 Angle of line at the bending shall be not less than 135°;
 Fixing pipe clamp on the solid control tank must be secure and reliable;
 Safety ropes or chains shall be set at both ends of relief pipeline.
b) When the drilling pump is running, do not open the safety shield on the relief valve to
avoid accidental personal injuries.
c) Before the cover of pulsation dampener is removed or the bladder of pulsation
dampener is replaced, gas in the bladder of pulsation dampener must be exhausted to avoid
casualty accident which is due to expansion of residual gases.
d) The pulsation dampener can only be charged with nitrogen or air. Flammable and
explosive gases such as oxygen or hydrogen are not allowed to avoid explosive accident of
pulsation dampener and personal injury accident.
e) For replacement of piston of cylinder liner, make sure the power machine and drilling
pump are at the closed state to prevent the casualty accident.
f) During running of drilling pump, inspect the fluid end quickly to avoid or reduce
personal injuries caused by leaked high pressure liquid.
 g) Operators could touch the reciprocating parts and even fall into the draw bar box. It
will result in casualty accident. Therefore, before using, inspect whether the shield on the
upper part of draw bar box is under the correctly closed state to ensure the protection
effective.
h) Fasteners on the rotational parts might get loose, drop and even fly off, which can
cause casualty accident because operator could touch the rotational parts. Therefore,
inspect whether the fasteners on the rotational parts are secure and reliable and whether
safety shields on the rotational parts are under the effective protection on a regular basis.
4.3 Damage to Equipment
a) Confirm the lubricating oil quality of power end is good, otherwise will cause guide
plate scratched, gear pitted, bearing damaged etc. make the drilling pump cannot work
normally. Mainly check the following items:
 When the sealing ring of pony rod damaged, the slurry or water will enter the oil
pool, causing lubricating oil quality changed, so the sealing ring shall be replaced timely.
 Regularly drain and clean the sediment from pollution discharge flanges that on
the sides of the rack, to insure the lubricating oil keep clean.
 After long time running of pump, in case there is abrasive grain or
corrosiveness compound in lubricating oil, it is required to replace with new lubricating oil;
 The type of lubricating oil shall be adjusted properly according to the operating
manual or nameplate specification based on the change in environment temperature.
b) Make sure that oil levels of lubricating oil in equipment are within the specified range
and cannot be lower than the lowest one particularly, or it will result in failure.
c) Make sure that the lubricating oil pump can be operated normally, or it will result in
failures such as bearing failure.
d) Inspect the overflow holes at sealing locations of fluid ends on a regular basis. If the
fluid is seeping, the operation of drilling pump shall be stopped and sealing ring shall be
replaced timely.
e) Correctly install and use the valve seats with a qualified quality to avoid the taper hole
damage of hydraulic cylinder by puncturing.
f) Correctly use the relief valve and make sure the safety pin is inserted into the correct
position; do not use the iron wire or welding electrode to replace the safety pin.
g) When the drilling pump is running, do not open the angle stop valve on the top of
pulsation dampener to avoid the damage of pressure gage. Charge pressure of pulsation
dampener shall be inspected under the closed state of pump (discharge pressure of pump
shall be zero).

5 For the other safety matters to be noted, please follow the related content specified
in different chapters of the context.
 Foreword

Thanks for purchasing F-1600HL drilling pump manufactured by CNPC Baoji Oilfield
Machinery Co., Ltd.
F-1600HL Drilling Pump Operation & Maintenance Manual includes one set of complete
data provided to users. The manual provides the corresponding guides for the installation,
use, maintenance and service of the product. This manual is prepared for F-1600HL drilling
pump (metric system), all connecting thread of this pump adopts metric system thread in
principle except for main bearing bolts.
This operation &maintenance manual is used by operating personnel and technicians
who have certain knowledge and are familiar with drilling equipment (or other equipment), so
that the manual is not expected to cover every situation you may encounter.
Parts of equipment operation and maintenance information are from manufacturer’s
manual. If the manufacturer publishes a updated operation and maintenance manual or the
old and new manuals have contradiction, the manufacturer’s data has precedence over the
information given in this manual.
Our company reserves the right to revoke (or change) product model and design at any
time without prior notice and bears no liability or obligation.
Please carefully read this operation & maintenance manual before installing and
using the products.
For the imperfection of this manual, we sincerely welcome your valuable advice and
suggestions!
 Table of Contents
SAFETY RULES ................................................................................................................................ I
FOREWORD ......................................................................................................................................V
1 NEW PUMP OPERATION .............................................................................................................1
1.1 TECHNICAL SPECIFICATION AND PERFORMANCE PARAMETERS .................................................1
1.2 NEW PUMP INSTALLATION ............................................................................................................. 4
1.3 REQUIREMENTS FOR SUCTION SYSTEM ....................................................................................... 8
1.4 PREPARATION FOR POWER END ................................................................................................... 9
1.5 SPRAY PUMP ASSEMBLY ............................................................................................................. 11
1.6 ASSEMBLING OF FLUID END COMPONENTS ...............................................................................12
1.7 PULSATION DAMPENER ASSEMBLY ............................................................................................ 17
1.8 SHEAR PIN RELIEF VALVE ........................................................................................................... 19
2 LUBRICATION ............................................................................................................................. 20
2.1 MINIMUM OPERATING SPEED ...................................................................................................... 20
2.2 SPLASH LUBRICATION FOR CONTROLLING FLUID ..................................................................... 21
2.3 PRESSURE LUBRICATING SYSTEM ..............................................................................................22
2.4 MAINTENANCE OF LUBRICATING SYSTEM .................................................................................. 24
3 MAINTENANCE ........................................................................................................................... 26
3.1 POWER END ................................................................................................................................. 26
3.2 ROLLING BEARING .......................................................................................................................27
3.3 PINION SHAFT ASSEMBLY ........................................................................................................... 28
3.4 CRANKSHAFT ASSEMBLY ............................................................................................................ 29
3.5 MOUNT THE CRANKSHAFT ASSEMBLY ON THE RACK ............................................................... 32
3.6 INSTALLATION OF THE CROSSHEAD GUIDE PLATE .................................................................... 33
3.7 INSTALLATION OF CROSSHEAD ................................................................................................... 34
3.8 INSPECTION OF CROSSHEAD CENTERING .................................................................................. 36
3.9 MAINTENANCE OF FLUID END ..................................................................................................... 37
3.10 REPAIR WELDING AND REPAIR ................................................................................................. 41
3.11 REPAIR OF BONNET HOLE ........................................................................................................ 43
3.12 REPLACEMENT OF BLADDER .................................................................................................... 43
3.13 APPROXIMATE WEIGHT OF EACH ASSEMBLY .......................................................................... 44
4 MAINTENANCE AND INSPECTION POINT ............................................................................ 45
4.1 DAILY MAINTENANCE ................................................................................................................... 45
4.2 WEEKLY MAINTENANCE ...............................................................................................................46
4.3 MONTHLY MAINTENANCE .............................................................................................................46
4.4 YEARLY MAINTENANCE ................................................................................................................46
4.5 OTHER MATTERS TO BE PAID ATTENTION DURING THE MAINTENANCE ................................... 47
5 POSSIBLE FAILURES AND SOLUTIONS ............................................................................... 51
5.1 FAILURE OF FLUID END ................................................................................................................51
5.2 FAILURE OF POWER END ............................................................................................................ 52
5.3 IN ADDITION TO THE ABOVE POSSIBLE FAILURES ...................................................................... 52
6 STORAGE PRECAUTIONS ........................................................................................................53
6.1 PROTECTION OF FLUID END ........................................................................................................ 53
6.2 PROTECTION OF POWER END ..................................................................................................... 53
6.3 STORAGE ......................................................................................................................................54
7 ORDERING INFORMATION ....................................................................................................... 56
7.1 SINGLE PUMP RANGE ...................................................................................................................56
 7.2 METRIC AND IMPERIAL PRODUCTS ..............................................................................................56
8 USE OF SPECIAL TOOLS ......................................................................................................... 57
8.1 ORDINARY VALVE SEAT EXTRACTOR - HOOK TYPE (WHEN USING ORDINARY VALVE ASSEMBLY)
.............................................................................................................................................................57
8.2 HOISTING TOOLS OF CYLINDER LINER AH130101-160100 ....................................................57
8.3 DISMANTLEMENT FRAME OF PISTON NUT AH130101-161400 ...............................................57
8.4 CONVERSION COUPLING (AH100101-2115) ............................................................................. 58
8.5 BOLT M24×220（AH130101-1611） ......................................................................................58
8.6 SLEEVE-- TOOL FOR DISMANTLING NUTS OF FLUID END ......................................................... 58
8.7 CONVERSION ADAPTER (USED TO TRANSITION THE SLEEVE FROM 19.05 TO 25.4) ...............59
8.8 CONVERSION ADAPTER（USE TO REMOVE THE HEXAGON SCREW OF THE DISCHARGE FLANGE）
.............................................................................................................................................................59
8.9CYLINDER HEAD ROD AH100101-210100 ................................................................................. 60
8.10 GAS-FILLING HOSE OF PULSATION DAMPENER AH100101-210700 .................................... 60
9 GUIDE FOR SELECTION OF LUBRICATING OIL .................................................................. 61
10 LIST OF PARTS OF F-1600HL DRILLING PUMP .................................................................62
10.2.1 GENERAL ASSEMBLY DRAWING OF F-1600HL DRILLING PUMP (AH160201-00) ............63
10.2.2 FLUID END ASSEMBLY AH160201-0100 ............................................................................. 66
10.2.2.1 PISTON（AH160203-010500） ....................................................................................... 68
10.2.2.2 CYLINDER LINER（AH160203-010600） ....................................................................... 68
10.2.2.3 VALVE ASSEMBLY（API 7）（AH160201-011900B1） ............................................... 69
10.2.2.4 DISCHARGE HYDRAULIC CYLINDER ASSEMBLY（AH160201-010400） ...................... 71
10.2.2.5 SUCTION PIPELINE（AH160201-010500B1） ............................................................... 72
10.2.2.6 SUCTION DAMPENER (AH000005-0800) ......................................................................... 73
10.2.3 5" AUXILIARY PIPELINE（52MPA）（AH160201-0200B1） ...........................................74
10.2.3.1 FILTER DRUM ASSEMBLY（AH160201-020200B1） .....................................................74
10.2.3.2 CONNECTING FLANGE ASSEMBLY（AH160201-020400B1） .......................................75
10.2.4 CRANKSHAFT ASSEMBLY（AH160101-0100） ................................................................. 75
10.2.4.1 MAIN BEARING END-CAP (AH130101-020100B2) .........................................................76
10.2.5 LUBRICATION ASSEMBLY OF POWER END（AH130101-0600B3） ................................. 77
10.2.5.1 SAFETY VALVE ASSEMBLY（AH100101-061400） ........................................................80
10.2.5.2 HYDRAULIC DISPLAY DEVICE（AH050101-060200B1） .............................................. 80
10.2.5.3 OIL PUMP GEAR ASSEMBLY (AH100101-061200) ......................................................... 81
10.2.6 PINION SHAFT ASSEMBLY（AH160101-0200） ................................................................ 82
10.2.7 HOISTING (AH130101-1000) ............................................................................................... 83
10.2.8 SPRAY PUMP ASSEMBLY (AH160201-1200B1) ..................................................................84
10.2.9 CROSSHEAD ASSEMBLY (AH130101-0400) ........................................................................85
10.2.10 JAF-3×52 FLANGE TYPE SHEAR PIN SAFETY VALVE (AH000006-1000) .....................86
SHEAR PIN SAFETY VALVE (AH000006-0300) ............................................................................... 87
10.2.11 WY-75-52 PULSATION DAMPENER（IMPERIAL）(AK755201-00) ..................................88
10.2.11.1 SHELL ASSEMBLY (AK755201-0100) ............................................................................ 89
10.2.12 SPARE PARTS OF F-1600HL MUD PUMP (AH160201-0800) ......................................... 90
10.2.13 TOOLS OF F-1600HL MUD PUMP(AH160201-0900) ...................................................... 90
10.2.14 HYDRAULIC VALVE PULLER（AH160201-090100） ....................................................... 91
10.2.15 DAMPENER INFLATABLE HOSE ASSEMBLY AH100101-210700 ...................................... 92
 1 New Pump Operation
BOMCO F-1600HL drilling pump is an important equipment of drilling rig. The
application is that transmit drilling fluid to the well bottom by high pressure manifold of
circulating system to cool the drill bits, clean the bottom of well, break stone, bring cuttings
and balance pressure of stratum etc.
The design and manufacturing of F-1600HL drilling pump conforms to the requirements
of API Spec 7K Drilling and Well Servicing Equipment.

1.1 Technical Specification and Performance Parameters

1.1.1 Technical Specification

F-1600HL Drilling Pump
Type Three cylinder single acting piston pump
Maximum bore diameter of liner (mm) 190
Rated power kW (HP) 1193(1600)
Rated stroke (r/min) 120
Stroke length (mm) 304.8

Gear ratio 4.206：1

Valve chamber API 7

Weight (kg) 30500

Nameplate of Drilling Pump

1
1.1.2 Performance Parameters
The performance parameters of the F-1600HL pump are shown in Table 1. It is strictly
prohibited to use it with overload! If the overload is more than 10%, the service life of its
bearing will be reduced by 27% compared with the design life. If the overload is more than
20%, the service life of its bearing will be reduced by 46%. If the overload is 100%, the
service life of its bearing will be reduced by 90%. It is recommended to use it under 80%
load for long-term, and the service life of its bearing will be increased by 110%.

Table 1 F-1600HL Performance Parameters (metric system cylinder liner)

Bore in
cylinder liner
diameter 190 *180 *170 *160 *150 140 130 120
（mm）
Rated
pressure 20.7 23.1 25.9 29.2 33.2 38.1 44.2 51.9
（MPa）
Rush
times rated
Time powe Displacement (liters/second)
s/min r/kW
ute
120 1193 51.85 46.54 41.51 36.77 32.32 28.15 24.27 20.68

110 1094 47.53 42.66 38.05 33.71 29.62 25.81 22.25 18.96
100 994 43.21 38.78 34.59 30.64 26.93 23.46 20.23 17.24
90 895 38.88 34.90 31.13 27.58 24.24 21.11 18.21 15.51
80 795 34.56 31.02 27.67 24.51 21.54 18.77 16.18 13.79
1 0.4321 0.3878 0.3459 0.3064 0.2693 0.2346 0.2023 0.1724

Note: 1. Calculate in accordance with volume efficiency of 100% and mechanical efficiency 90%.
2. Maximum working pressure 51.4MPa.
3. The specifications of the cylinder liner with * can be used with the cylinder liner of F-1600
pump, and special wear-resistant discs (φ180) should be used at the same time.

1.1.3 Overall Dimension

The overall dimension of F-1600HL drilling pump is detailed in Fig. 1.

2
Fig. 1 Overall Dimension of Drilling Pump

3
1.2 New Pump Installation

When Ex-work, the following parts of F-1600HL drilling pump have been dismantled and
packed into the accessory box, air filter (connecting part shall be plugged tightly), 5” auxiliary
piping, pulsation dampener and relief valve, etc. And the pump shall be subject to loading
test and the lubricating oil will be discharged from power end. Preventive measures shall be
taken to operate and check it before operation. The equipment must be powered off and
stopped and all the protective shield device on prime mover and drive device must be in
safety position in case of occurrence of human injury during maintenance and check.
The foundation under BOMCO F-1600HL drilling pump shall be suitable for all types of
installation. However, the supporting foundation under the pump must be in horizontal
position and shall be with adequate strength so as to support the net weight of the pump and
strength occurred during rotating.

1.2.1 Hoisting Requirement

In order to ensure the hoisting safety, it’s advised to use 4 individual steel wire ropes,
the length shall not shorter than 8 meters, and the breaking force of each individual steel
wire ropes shall not less than 40T.

Fig. 2 Hoisting Diagram

1.2.2 Installation on Ground

At least 8 spacers with dimension of 76×305mm shall be applied on the foundation of
pump while ground installation. Positions are shown as Fig. 3. The foundation under the

4
bottom plate must be 300mm(11.8in) wider than the main body of base beam of the pump.
More stable foundation is needed for damp or swamp area.

Fig. 3 Ground installation diagram

1.2.3 Permanent Installation

The pump shall be installed on the structural or cement foundation on drilling ship or
drilling platform and the foundation of pump be fixed by bolts. It must be bedded by spacer of
the foundation in case of possible distortion or inclination of rack at power end and the
foundation of pump must be firmly on all spacers when the bolts are loosening.
When it is installed on the ship, the base of pump is always connected on T-type beam
by bolts and the installation of spacers on each point is detailed in Fig. 3 and Fig. 4. Proper
plates shall be added in case of distortion and inclination. All spacers must be over the width
of the projecting edge of base beam with min length of 305mm.
When the prime mover, drive device and base of pump are installed as integral part, the
pump shall be installed on the base of T-beam with stopping block and bolts shall not be
applied. It could allow “floating” of the pump and largely reduce the possibility of distortion of
rack due to distortion of shipboard or platform.

5
泵底座: Foundation of pump
垫片: Spacer
T 型钢: T-type steel
台板: Plate
Fig. 4 Foundation of New Pump

1.2.4 Installation of Drive Device

V-belt or multi-row chain could be applied for driving of pump and prime mover. It must
be accurately installed to ensure the max operating life and min frequency of stopping
machine due to driven faults.
When drive belt or chain wheel is installed, anti-rusting agent or grease on the mating
hole and shaft head shall be cleaned. Clean fin, protuberance on the key, key slot and shaft
head to ensure that the key is closely matching with the key slot on the shaft and driven
components.
Apply light lubricating oil or anti-coherer oil on the pinion shaft head and install the belt
hub or chain hub, screw the bolts as per the following description:
Screw torque N·m (lbf.ft) Length of wrench mm (in) Strength on the wrench N (lbf.ft)
810 900 900
When wrench or extension bar is applied to screw the bolts, it may cause over torque.
Therefore, we shall continuously screw the bolts as per the torque values given above. It is
important to do that because the strength for screwing bolts for installation of wheel hub will
be increased sometimes due to effect of conical surface and the strength will force the wheel
hub to tightly wrap the wheel hub. When the strength of fasten bolt is over, it will create more
expansion strength and cause broken of wheel hub. Thus, the bolts for wheel hub shall be
screwed by symmetrical, crossing, uniform and successive methods.

1.2.4.1 Driven by V-belt

6
 1) Check the state of groove of pulley
Check if the groove of pulley becomes round after abrasion before installation. V-belt
will be damaged by the groove after abrasion. The wall of groove must be straight without
sewage or projecting part inside.
2) Check the centering of pulley
3) Adjusting the pre-tightening force of V-belt
Move the central distance of pulley to adjust the tension of belt until the tensioning side
of the belt is not down and the belt at loosen side will also be tensioning and increase a
certain central distance. For example, after the central distance is adjusted to 2540mm
(100″), increase 13mm (1/2″). When the central distance is 3810mm (150″), increase 19 mm
(3/4″) for the central distance after adjustment.
Do not gain tension of belt by means of padding the end of pump and low down the
pump end on the ground to tension the belt by net weight of the pump.

1.2.4.2 Driven by Chain

1) Installation
Right installation and maintenance are necessary methods for gaining better service life
of chain driven and chain driven device. For many reasons, such as width of chain, central
distance, speed and load, that shall be taken into account for confirming the tolerance of
centering of chain wheel. However, there is not a completed “Practice Rules” could be
applied. Therefore, centering for chains must as accurate as possible. The more accurate
method for centering is that tensioning on one surface alongside the two chain wheel by two
steel wires (piano string), one is on the center line and one is under it, move one chain wheel
to make the two steel wires contact with the four point of chain wheel, it could be confirmed
that the two chain wheels driven are centering and the center line is parallel and it is vertical
to the shaft line.
2) Lubrication of driven chain
Chain lubricating system in the chain driven device of F series pump is a separate
system with its own lubricating pump, oil tank and driven. The lubricating oil will filled into the
chain box to reach the indicated height of fluid level. Selection for brand of lubricating oil
could refer to Selection Guideline for Lubricating Oil of BOMCO Product.
When the temperature is less than -18℃ (0°F), consult supply department of lubricating
oil and take their advices.
The applied lubricating oil shall be in accordance with relevant norms of lubricating oil

7
and lubricating manual compiled as per the specifications.
Chain lubricating system is a separate system. Thus, it need to be repaired and
maintained as other machinery equipment. It includes:
——Check oil level every day;
——Check status of lubricating oil every day;
——Check oil pressure 0.035 MPa～0.103 MPa（5psi～15psi）
——Supply certain mount oil for the chain;
——Check the working condition of oil nipple on the spray pipe;
——Check the working condition of driven of oil pump (V-belt or chain).
Note: ① Relief bolt behind the pump foundation is used to adjust the oil pressure.
② When the oil pressure reduces or is too high, the filter screen for suction shall
be cleaned.

1.3 Requirements for Suction System

The design for suction system of pump shall meet the requirements of separate
installation. F series pump must be with positive pressure head (positive pressure) so as to
get satisfying suction performance. The preferred pressure of suction manifold is 0.14 ～
0.21MPa (20～30psi) so that the pump will have maximum volume efficiency and longest life
of wearing parts. The pressure head could be gained by 6×8 charge pump. The charge
pump shall be started prior to drilling pump. Stimulate the electromagnetic starter by one
signal gained on D.C control panel on the drilling rig driven by D.C motor.
The charge pump could be driven by belt and the driven force is originated from the
pinion shaft of drilling pump.
Suction pipeline shall be arranged to connect the bypass of charge pump. When the
charge pump is with faults or is repaired, the drilling pump could continue working. When
there is no charge pump and the drilling pump works, some suction valve springs can be
replaced to improve the suction performance.
Suction pulsation dampener is a very effective auxiliary device and it could improve
suction performance and eliminate the liquid flow pulse of suction pipeline to stably
discharge liquid flow. The following operation and check must be conducted before operation
of the pump.
Note: Do not connect the back-flow pipeline of shear pin relief valve to the suction
pipeline, because when the shear pin relief valve is opened, the pressure inside the system

8
will suddenly rising. When it is higher than the rated pressure of suction system, the manifold,
suction pulsation dampener and centrifugal pump will be damaged.

1.4 Preparation for Power End

F-1600HL pump must be completely assembled and subject to frame running test and
the lubricating oil inside the power end shall be discharged before delivery. The following
operation and check must be conducted before operation of the pump.
Note: When delivery, air filter C-M60×2 on the top of rack is dismantled and packed into
accessory box, and plugged by plug. So the plug shall be removed, and reinstall air filter
C-M60×2 before use.

1.4.1 Lubrication of Power End

Open the inspection door on the cover, to check if lubricating oil inside the power end is
altered before filling lubricating oil, if altered, open the pipe plug besides the pump (Fig.8-No.
2) and discharge all stored oil and clean it. The lubricating oil with specified brand number
and quantity (nameplate on rack) must be filled into the power end.
After 15min operation of the pump, check the oil level again. Stop the pump for 5min to
stabilize oil and check the oil mark (Fig.8-No. 1). More than 10L (3 gallons）lubricating oil
must be supplemented for there is a certain amount of oil in the crosshead and cavity of
rack.

1.4.2 Installation for sealing of pony rod and packing box

Fig. 5 Packing box seal installation

(1) Packing box (2) Bolt (3) Spacer (4) Gasket (5) Double-Lips oil seal (6) Oil seal ring
(7) O-ring (8) O-ring (9) Locking spring (10) Bolt (11) Bolt (12) Spring

9
 As the Fig. 5 shown, remove the packing box (1), rotate the pump manually to make the
crosshead is in the front end of the stroke. Thoroughly clean the forepart of crosshead and
the end surface of the pony rod, and then mount the positioning boss of the pony rod to the
hole of crosshead. Tighten the bolt (2) with the torque of 566N.m(415lbf•ft), and then lock up
with iron wire. Thoroughly clean the end surface between fender plate and rack, mount
sealing gasket (3) (Fig.5 - “A”) and bolt (10), screw the bolt with torque of 68N•m (50lbf•ft).
Clean the outer surface and flange surface of the packing box, apply the outer surface
of the packing box with light oil and install the gasket. Fill the packing box onto the fender,
tighten the bolt (11).
Packing box assembly includes: lips oil seal (5), oil seal ring (6) and O-ring (7), O-ring
(8), lock spring (9), spring (12) and so on. The method of installing the assembly is as
follows,
Method 1:
1) Remove the spring (12) from the double lipped oil seal (5), mount the oil seal to the
external of the pony rod. The main lip is towards to the power end, and then the spring (12)
is mounted to the oil seal lip, push them to the packing box. Refer to the Notes below.
2) Install O-ring (8) into the sealing ring (6) and install it on the bar and then install it
inside the hole of packing box.
3) Install O-ring (7) into the slot of packing box.
4) Install the double lipped oil seal (5) in Fig. 5. The method is the same as step 1).
Note: the double lipped oil seal (5) on the side of the power end could be replaced
by single lipped oil seal. But single lipped oil seal could not be applied to the outside
(fluid end) one.
5) Install locking spring (9).
Method 2:
1) Take off the packing box (1) from the rack. Pack the double lipped oil seal (5), sealing
ring (6) and O-ring (7), O-ring (8) and locking spring (9) in the packing box (1) according to
the partial enlarged drawing in Fig. 5, and then cover the gasket (4) in the outer cylindrical
surface of the packing box (1).
Install the guide sleeve (attached tools) at the front end of the pony rod as shown in Fig.
5, and then apply the light lubricating oil on the external surface of the pony rod and the
guide sleeve.
Mount the packing box assembly on the pony rod through the guide sleeve, and push in

10
place manually, and then install the packing box (1) on the fender plate with the spring
washer and bolt (11).
Note: It is necessary to guarantee that the pressure spring (12) will not be slipped
out of the oil seal lip when the crosshead rod is seriously scratched. Apply the draw
rod with light oil so that the packing box assembly is easily installed.

1.5 Spray Pump Assembly

Spray pump assembly includes spray pump, water tank and nozzle, etc. The function is
to clean and cool cylinder liner, piston and seals during operation to improve its service life.
Spray pump is the centrifugal pump, driven by the AC motor. Recommend cooling fluid
is consisted of 10% JH-I water base lubricating coolant and 90% clean water. Then stir well.
The nozzle is fixed on the frame above the cylinder liner. When the piston moves, the
nozzle does not move, called "fixed" type.
F-1600HL metric drilling pump adopts the fixed spray pipe as shown in Fig. 6, including
nozzle (1), steel pipe (2) and spray pipe (3) which fixed on the frame. It shall spray the
cooling liquid to the cylinder liner and piston. Adjust the water supply of manifold and often
check the nozzle to let the sprayed fluid directly on the piston.

Fig. 6 Spray Pipe

(1) Main Spray pipe (2) Spray pipe (3) Nozzle
The cooling fluid is transmitted to the manifold located at the left (right) wall of rack from
spray pump (Fig. 8, No. 3) to water tank (Fig. 8, No. 5). The regulating valve (Fig. 8, No. 4)
shall provide water for spray on the piston of cylinder liner as much as possible. It is
preferred that it not spray on the draw bar of crosshead and avoid that litter water will return
the power end and pollute the lubricating oil.
The cooling fluid will return to the sediment chamber of water tank from the front
chamber. When the cooling fluid flow from the strainer, the solid substrates as mud water will
become sediment and the foreign matters will be blocked by the strainer as shown in Fig. 7.

11
 Suction pipe of spray pump
Strainer
Semimetal Water outlet
chamber

Fig. 7 Water Tank of Drilling Pump

Fig. 8 Spray System of Drilling Pump

(1) Oil level indicator (2) Pipe plug (3) Spray pump
(4) Regulating valve (5) Water tank
Regularly check the cleaning situation of cooling liquid. Clean and wash the water tank
and change the cooling fluid as per requirements. Due to increased sand of polluted fluid,
piston and cylinder liner will be worn or the spray pipe will be blocked.

1.6 Assembling of Fluid End Components

Cross-section of fluid end of F-1600HL is shown in Fig. 9. Clean and assemble the
components of fluid end as per the following methods.
Note: Metal to metal installation is designed for many components at fluid end. It
could reduce wearing by high pressure fluid flow during operation of high pressure
pump. For this reason, it is necessary to require that all the components must be
clean before installation. It shall be without vices as fin, scrap and rust that could

12
influence the quality of products to ensure the reliable sealing of fluid end.

Fig. 9 Fluid End Assembly of F-1600HL Drilling Pump

(1)Discharge hydraulic cylinder (2)Wear plate (3)Discharge pipeline (4)Suction hydraulic cylinder
(5)Piston (6)Cylinder seals (7) Discharge pipe seals (8) Wear pleas seals (9) Liner seals (10)
Cylinder liner (11) Liner locking ring (12) Bonnet seals (13)Valve spring(14) Valve assembly API 7
(15) Clamp assembly (16) Liner end cover (17)Liner cover (18) Liner flange (19) Spacer unit (20)
Gasket 39 (21) Spray pipe assembly (22) Piston Seals (23) High pressure valve assembly（24）Wear
plate (25) Piston rod (26)Suction pipeline (27)Bonnet (28)Bonnet plug (29)Screw M24
(30)Gasket (31)Valve stem guider (32) Baffle

1.6.1 Valve, valve seat

Assemble the valve body, valve rubber into a whole by plate and locking spring. Clean
the external conical surface of the valve seat, and confirm the external conical surface
without nick or burr. Put the valve seat into a cleaned cylinder valve cone hole.
When assembling the valve seat, it is better to find an old valve body to keep on it. Hit
three times with an iron bar, and then take out the valve body and check whether the valve
seat is fixed or not. If there is no old valve body, shall hit around top edge of the valve seat
evenly with a copper bar to make it closely fit the hydraulic cylinder.
Note:
1.When assembling, it is strictly prohibited to coat oil or grease on the external
conical surface of the valve seat and the internal surface of the valve seat hole.
2.The old valve body shall not be used on the newly replaced seat.

13
1.6.2 Bonnet
Install the valve assembly (14) on the seat. Make the valve spring in the central position
of the valve body and compress it with the bonnet (27).
Install the bonnet seals (12) coated with grease on the shaller of cleaned hydraulic
cylinder. After assembling the bonnet and the valve stem guider (31), coat the thread surface
of the bonnet (27) with grease, and then screw tightly with the round bar.
Before installing the bonnet (27), put the cushion and the valve stem guider into the
bonnet. The valve stem guider is composed of a guiding body and an inner sleeve. Check
the inner sleeve during the replacement of the bonnet seals. And replace with a new inner
sleeve, when the old one is worn or damaged. When replacing, cut and take out the old inner
sleeve, and then use the attachment tools (bolts, nuts and washers) to press the new inner
sleeve in, as shown in Fig. 10.

Fig. 10

The suction and discharge valves are interchangeable.

When the working pressure is no more than 35MPa, shall use the ordinary valve
(API 7 #). When the working pressure is greater than 35MPa, shall install the high
pressure valve (API 7H).

1.6.3 Assembling of piston and its assembly with the cylinder liner
Clean the piston (5) and piston rod (25) to ensure there is no burr or scratch. Install
the piston seal (22) into the groove of the piston core. Install the piston (5) on the piston
rod (25), and be careful not to let the O-ring slip. Rotate the nut on the piston rod with a
torque of 2152N • m (1587 lbf • ft).
Coat the grease on the inner circle of the cylinder liner and the outer circle of the piston.
Check the piston rod (25) and the pony rod end to ensure them clean without burr. Put the
piston rod (25) into the cylinder liner, so that the piston rod keeps in the middle at the
backside of the cylinder liner. Hit the piston into the cylinder liner with hardwood or special
tools. Note that hold the piston rod to make it into the positioning hole and not to damage the
positioning boss at the end of the piston rod, when approaching the pony rod.
Shall install the piston with the cylinder liner outside the pump body in advance, and

14
then lift them together onto the hydraulic cylinder. The assembly and disassembly
procedures are the opposite steps. When installing the piston with the cylinder liner, must
coat the inner surface of the cylinder liner and the outer surface of the piston with calcium
base grease in advance, and then install the clamp of the piston rod and the pony rod.

1.6.4 Installation of cylinder liner

The wear plate seal (8) is fitted into the counter bore of the discharge cylinder (see
Figure 9). Install the wear plate (2) with the studs in place. And install the flange(18), in the
assembly to make the starting point of the thread on the lower right corner, equivalent to the
clock on the 5 o'clock position, with 566 N • m (420lbf • ft) torque tightening liner flange nuts.

Note: The starting point of the thread at 5 o'clock position is to make the cylinder
cover gland thread easier to engage.

Install the wear plate seal (8) into the counter bore of the wear plate (2). Coat the grease
on the inner surface of the liner cover gland (17) and then cover the cylinder liner (10) from
the rear. Place the halves liner locking ring (11) in the liner groove with O-rings. Lock the lock
ring of halves liners with O-ring. The rack is equipped with a small crane for lifting cylinder
liner. The maximum lifting capacity is 500kg. Use a spreader to lift the cylinder liner (10) from
the top. Coat grease on the cylinder gland thread. Make the starting point of liner cover
thread equivalent to the position of 7 o'clock on the timepiece, put the cylinder liner into the
cylinder liner flange (18), tighten the cylinder liner gland (17) so that cylinder liner seat is in
place. Tighten the cylinder liner cover with hammer.

1.6.5 Piston rod clamp

The whole clamp is divided into two pieces after processing. Two pairs are marking with
a pairing number and linked together with the chain. The two parts with the same pairing
number shall be used together for a group of clamps on the piston rod and the middle tie rod
flange. Tighten the bolt with a torque of 566 N · m (420 lbf • ft).

If both the piston rod and the clamp are new, the gap between the two halves of the
clamp has a gap greater than 5.5 mm. So that the piston rod end faces a good
metal-to-metal connection. When worn, the two halves will tend to approach. If the gap does
not appear, the clamp does not work, shall replace the clamp. Install the baffle at the rear of
the cylinder to prevent water splashing.

1.6.6 Discharge pipeline

15
 The flanges of the discharge lines and the discharge ports are 5 1/8 "API 10000 psi.
After removing the discharge flange and the gasket ring, the flange is welded to the
discharge line (the welding method shall be selected by the user). With 843N • m (620 lbf • ft)
torque, tightening flange coupling bolts. Tighten nuts with a crossed manner.

1.6.7 Suction pipe flange

There are three 305mm (12") connecting flanges on the suction pipe. Normally,
according to the well site situation, one flange is connected to the suction pipe inlet. One
flange is connected with the suction dampener. The last one is with blind plate. And flange
connection shall be sealed with O-ring. F. Before connecting, clean O-ring groove and flange
end face, then tighten the bolt with 266N • m (195lbf • ft) torque.

1.6.8 Auxiliary pipeline

The auxiliary pipe is shown in Fig. 11. Can be installed in the discharge pipe on the
opposite side of the discharge. This pipe can be connected with WY75-52 pulsation
dampener (1), shear pin safety valve (3) and pressure gauge (2).

Fig. 11 Auxiliary pipeline

(1) Pulsation dampener (2) Pressure gauge (3) Shear pin safety valve (4) Rim (5) Flange bolt
(6)5-wany discharge (7) Rim (8) Nut (9) Rim
The auxiliary and the discharge pipelines are connected by flange. Before installation,
thoroughly clean the sealing groove on the flange, put the rim (4) and tighten the flange bolts
(5) with the tightening torque of 843N • m (620 lbf • ft), to ensure uniform tightening of the rim
connector. The gap of the flange end shall be uniform and used cross-tightening.
The auxiliary pipeline is also equipped with shear pin safety valve (3). When the pump
pressure exceeds, the specified value rapidly blows off to ensure the safety of drilling pumps.
The safety valve must be installed correctly and contact directly with the mud. And any type
gate shall not be allowed between the discharge line and the safety valve. Connect the
safety valve outlet with a seamless steel pipe directly to the mud pool. This seamless steel

16
pipe shall be bent as little as possible. It is advisable to direct the discharge end of the safety
valve to the suction pipe of the pump.
The flange at the bottom of WY75-52 pulsation dampener is equipped with a gasket ring
of BX155. Before installation of pulsation dampener, thoroughly clean the rim and groove.
Then tighten the nuts (8) with a 1193N · m (880 lbf • ft) torque. Use a crisscross pattern to
tighten it evenly.
Both sides of the 5-way discharge (6) are the flanges of the rim BX-169. Before
installation, thoroughly clean the rim and groove, the coupling bolts and nut with torque of
843N • m (620lbf • ft) to use the cross-way evenly tightened.
Before starting the pump, pre-charge the pulsation dampener with air or nitrogen. See
the description of "pulsation dampener assembly" section.

Fig. 12 WY75-52 pulsation dampener assembly

(1)Shell assembly (2) Cover (3) Pressure gauge cover assembly (4) Bladder assembly (5) Rim (6)
Tee (7)Joint (8) Exhaust valve (9)Pressure gauge (10)Stop valve (11) High temperature bladder
assembly (R1)Nut (R2) Nut

1.7 Pulsation Dampener Assembly

Correct installation and application of pulsation dampener could effectively reduce the
pressure fluctuation of exhaust system to gain more uniform fluid flow. Often keep
recommended proportion of pump pressure and pre-charging pressure of bladder in order to
gain longer life of bladder. Generally, it will not be over 2/3 of exhausted pressure of the
pump. However, it shall not be over 8.6Mpa(1250psi). Both the capacity and the

17
compressive strength of the dampener meet the requirements of the drilling pump. The
dampener shall be filled with nitrogen or air. But oxygen, hydrogen and other flammable and
explosive gases are not allowed.
The stop valve of pulsation dampener shall be closed after charging. The pre-charge
pressure is 8.6MPa (1250psi). Close the stop valve to protect the pressure gauge after filling.
Long-term work under low pressure cycle pressure, the baldder usually exhausr the
pre-charge pressure.

1.7.1 Installation
Structure of WY75-52 pulsation dampener is as shown in Fig. 12. The lifting lugs
installed on the pressure gauge enclosure (3) are used to hoist pulsation dampener
assembly. The sealing groove, rim and sealing groove of coupling flanges must be
completely cleaned before installation and coated with grease.
Hoist the pulsation dampener to the corresponding position of drilling pump discharge
pipe, and screw the bolts (R2) with the torque of 1193N.m(880lbf•ft). Keep the connecting
part straight and centering when screw and therefore, crossing method shall be applied to
screw bolts.

1.7.2 Inflation
The pump is equipped with gas-filling (Dampener inflatable hose assembly) Ex-work. It
shall be operated as per the following steps and shown in Fig. 13.
1.Remove the pressure gauge enclosure of pulsation dampener, rotate 1/4-1/2 circle of
exhaust valve and exhaust the gas pressure in the pressure gauge and take off the valve
bonnet of exhaust valve.
2.Connect the hose to the switch of nitrogen cylinder and gas-filling valve of pulsation
dampener.
3.Open the gas-filling valve of pulsation dampener.
4.Slowly open the nitrogen cylinder valve and adjust the gas in the pulsation dampener
by this valve.
5.When the pressure of pulsation dampener indicates the necessary pressure, close the
cylinder valve.
6.Close valve of pulsation dampener.
7.Remove the hose, cover the pressure gauge enclosure and install exhaust valve.
The filling pressure of pulsation dampener shall not be over 2/3 of exhausted pressure
in order to get best results. But the maximum filling pressure is 8.6MPa(1250psi).

18
 Warning!
1. When charging, only the compressed nitrogen or air can be used – the oxygen
or hydrogen and other flammable gases cannot be used.
2. The pump must be stopped when maintaining the pulsation dampener, and
ensure that the gas in the pulsation dampener is discharged off. Do not judge them
with the pressure gauge, since the residual pressure is small, which cannot be
displayed in the pressure gauge. But the low pressure will also cause an accident!

Charging Valve of Dampener

空气包充气阀
Switch 氮气瓶开关
of Nitrogen Cyliner

1 2 3 4 5 6

Fig. 13 Dampener inflatable hose assembly

(1)Nut (2)Seals joint (3)Hose (4)Joint (5)Gasket (6)Plug

1.8 Shear Pin Relief valve

Fig 14 Shear Pin Relief valve

(1) Nameplate (2) Inlet flange (3) Piston rod (4) Valve body (5) Cushion (6) Outlet flange
(7) Transition sleeve assembly (8) Locking spring (9) Safety cover (10) Shear pin plate
(11)Shear pin (12) Pin (13) LabelⅠ (14) LabelⅡ (15) Gasket (16) Piston assembly (17) Gasket

The JAF-3×52 flange type shear pin relief valve is shown in Fig. 14. When the pump

19
pressure exceeds the rated value, the acting force on the piston assembly (16) will jack up
the shear pin plate (10) to compel the shear pin (11) broken, and the liquid is rapidly
emptied.
JAF-3 flange type shear relief valve can change the discharge pressure by changing the
position of the shear pin. It’s easy to operate and reliable to work.
At the shear plate of the shear pin type relief valve is marked with the working pressure
of each grade. When regulating the pressure, just insert the safety pin to the appropriate
hole according to the pressure. Note: Maximum 2 pins could be inserted into the shear plate.
When the cylinder liner is changed in size, the position of the safety pin must be adjusted
accordingly so that the pressure corresponding to the safety pin is slightly higher than the
pressure that the cylinder liner can withstand.
Steel wire, electrode or other materials are not allowed to be used to replace shear pin.
It could influence the pressure value of relief valve and could cause accident.
There are three sizes of relief valve inlet: 2 1/16” flange type, 3 1/16” flange type,
3″-1502 union type for selection of users.

2 Lubrication
It is important to lubricate the moving components, because it directly influences the life
limitation of machinery components. It must carry out maintenance and check to gain the
longest life without faults of the pump and ensure that suitable clean lubricating oil shall be
on the surface of every moving component.
F-1600HL drilling pump is equipped with the oil bath splash lubrication and pressure
lubrication system to lubricate the entire power end, and various types of pressure
lubrication control the minimum stroke per minute of the pump in operating. That is to say,
the minimum speed of the pump only makes pressure lubrication for the main bearing and
pinion bearing is 40 strokes / min. But as to the pump makes pressure lubrication for parts
such as bull gear bearing and pinion shaft bearing, crosshead bearing and crosshead, etc., if
the minimum oil supply pressure is 0.035 MPa（5psi）, the minimum operating speed is 25
strokes / min.

2.1 Minimum Operating Speed

The F-1600HL drilling pump adopts the oil bath splash lubrication and pressure
lubrication system for the entire power end. The form of pump pressure lubrication limits the

20
minimum stroke of the pump in operating, and the F-1600HL drilling pump can work at the
speed of 25 strokes / min (if the oil pressure is 0.035 MPa).
Note: The pressure lubricating oil pump can be installed outside the mud pump
driven by AC Motors, or installed inside the pump (driven by the bull gear of the
pump). When using the latter oil pump for lubrication, the direction of rotation of the
pinion shaft shall be as shown in Fig. 15.
Pinion
Bull gear

Oil pump gear

Fig. 15 Drilling pump power end rotation

2.2 Splash Lubrication for Controlling Fluid

In the splash lubrication system that control the fluid flow, bring the oil from the pool with
the bull gear. When the bull gear and pinion is engaged, the oil will be splashed into the
sump and the chamber of rack. As shown in Fig. 17, when the oil is thrown to the oil sump
(7), it will pass through the oil pipe (8) to flow to the bearings of two bearings of pinion shaft.
Flow into the oil passage of crosshead bearing from the top plate of crosshead is
detailed in Fig. 16. The lubricating oil will accumulate in the chamber on top of crosshead,
and will flow into the baffle of crosshead by nipple (1) and into the oil passage (5) to lubricate
the crosshead pin bearing. As shown in Fig. 16, the cross pin has two oil passages (5) that
allow the crosshead pin to rotate without having to worry about the alignment of the oil hole,
so that the crosshead can be loaded from either direction during installation.

21
 Fig. 16 Crosshead Lubricating Oil Passage
(1) Oil nipple (2) Baffle (3) Bolt (4) Crosshead pin (5) Oil passage

2.3 Pressure Lubricating System

The pressure lubricating system of F-1600HL drilling pump is equipped with lubricating
pump as shown in Fig. 17. In this system, the filtered oil shall flow into the pump through the
suction filter (1), and then drain to the oil separator (2) and nozzle (3A). Besides, it also
enters the oil pipe of main bearing oil pipe (4) and crosshead chamber oil separator (4A).
This oil separator can distribute the oil to the crosshead, crosshead bearing and piston rod.
The pressure gauge (5) is mounted on the back wall of the rack to indicate the oil pressure of
the oil separator. The pressure varies with the pump speed. However, if the oil pressure
suddenly reduces or rises, refer to the “maintenance of lubricating system”, to identify
possible causes and exclude them in a timely manner.

22
 Fig 17 Pressure Lubricating System
(1) Filter (2) Oil separator (3) Oil pipe (3A) Nozzle (4) Main bearing oil pipe (4A) Oil separator
(5) Pressure gauge (6) Relief valve (7) Oil sump (8) Oil pipe (9) Lubricating pump

A relief valve (8) is mounted on the oil separator (2) to prevent damage to the
transmission of oil pump due to excessive pressure. The working pressure of relief valve is
0.5MPa（72.5psi）, and shall be locked (to prevent the change of the regulated pressure).
When installing the internal assembly type lubricating pump (9), position the oil pump.
Make the back of the transmission gear parallel and level to the side of the bull gear of the
mud pump, and there shall be 2.0 mm ~ 2.5 mm（0.079"~0.098"）clearance between teeth.

(1) Lubricating pump (2) V-belt (3) Shield

Fig.18 External Power End Lubrication
A typical external lubrication pump is shown in Fig. 18. Through oil pump (1) to use pipe

23
connecting pipeline of lubrication system by suction and discharge joint at the bottom of left
and right wall panel of power end. V-belt (2) do not adjust too tightly to prevent early damage
to the pump. To prevent possible incident, install the belt guard (3) before operation.

2.4 Maintenance of Lubricating System

It is a key factor for extending the service life of pump by complete lubrication of moving
machinery components. It is necessary to carefully maintain the lubricating system by the
operators and lubricating situation will decide the period of service life without faults of the
pump.

2.4.1 Lubricating Specification

Recommendation of lubrication is shown below and also could be referred to Selection
Guideline of Lubricating Oil of BOMCO Products. This information can be found in the
nameplate on the side of the pump. The documents are based on the long-term test results
of oil field. The replaced oil could only be applied in emergency situation.

2.4.2 Oil Tank

Capacity of oil tank is 379L (100 U.S. Gallons)
Note: After 100 hours of drilling pump operation at the first time, lubrication oil
shall be replaced timely to drain out the foreign substance from new pump chamber.

2.4.3 Routine Check

Check one time for ever shift. To check the oil level and keep it on the full mark of the oil
standard. The pump must be shut down for about 5 minutes to stabilize the oil level before
check.
Check it every six months. If there is abrasive particle or corrosive matters in the oil, it
must be discharge one time and clean the oil tank and then add new one. Drain port is at
side of pump rack. During spraying, completely clean all oil sumps and chamber on the
guide plate of crosshead. Simultaneously clean or change the filter element of respirator and
clean the suction strainer. Before adding new oil, to remove the sewage flange, remove
sediment.
Periodically check the condition of lubricating oil. The oil shall be often changed due to
entry of damp, moisture, dust and mud.
The sediment chamber is located at the crosshead guide plate section of the power end,
and the oil dirt spilled into the chamber shall be precipitated. The oil discharging cover of the

24
sediment chamber is located at the two sides of the rack under the crosshead inspection
door, and you shall open the cover to discharge sediment.
Check it every month and remove the oil-discharge cover of both sides, the oil with
sediment will be discharged and about 15-gallon oil will loss. Therefore, certain amount oil
shall be added to supplement the lost oil.
Check it ever week and remove 1/2″ plug of the bottom part of flange and drain the
accumulated water.
Check by every shift. Check the oil level in the main oil tank to keep the oil level is on
the full mark. If pressure is decreasing, check the following items,
-If the strainer is blocked
-If the oil level is lower
-If the V-belt is slipping
-If the joint is loosened or broken
-If the oil pump is broken or damaged
-If the relief valve has faults
If the oil pressure is increasing abnormally, check the following items,
-if the oil passage is blocked
-if the sediment with oil-coherence
-if the relief valve does not work
-if the pressure gauge is damaged
-other conditions.

25
 3 Maintenance

3.1 Power End

Routine checks of the power end are the most important way of preventive maintenance,
which can help discovery of various defects. Necessary check is required for the existing
faults or during rig movement.

3.1.1 Check Pre-tightening force of main bearing bolt

Tightening torque of main bearing bolt is 13210 N•m(9750lbf•ft).

3.1.2 Locking wire

Check all bolts (including the main bearing cap bolts, the locking wire of bearing baffle
bolt end of crankshaft. After re-tightened the bolts, replace the wire. For the requirements for
the tightening torques, please refer to the chapter of crankshaft assembly).

3.1.3 Oil pipe

Check all oil pipes to ensure that they are intact and unblocked. Check whether the
pump suction hoses are damaged or pressed flat.

3.1.4 Suction filter

Check filter. If necessary, please clean or replace it.

3.1.5 Main bearing cap

Remove the main bearing cap, check the conditions of main bearing stop bolt fastening,
roller bearings and so on. Clean and remove any scum and foreign matter, because they will
accumulate to the bottom of the bearing area.

3.1.6 Teeth of bull gear and pinion

Check whether the bull gear and pinion have abnormal wear. During the running-in
period, there will be some spots on the tooth surface. This is the "initial pitting", which has no
impact on the gear life. However, if the pitting is discovered expanded in the routine
inspection, it is necessary to immediately contact with the pump OEM to conduct a thorough
inspection of the gears.

3.1.7 Crosshead pin bolts and crosshead guide plate

Remove the crosshead hole cap and check the crosshead pin bolts and locking wires
(when checking the middle crosshead pins, remove the back cap and switch the linkage to

26
the outside dead point). Tighten the crosshead pin bolt with torque of 290～310 N•m （215～
230lbf•ft）.
When using the torque wrench, do not exceed the above values.
If abnormal wear and tear of crosshead or guide plates occurs, replace them
immediately. Since may cause damage to bearings and other parts, and excessive wear will
accelerate the wear and tear of pistons and cylinder liners.

3.1.8 Lubricants and oil tanks

Check the oil condition and cleanliness of the tank and conduct maintenance and
services on the lubricating systems according to the measures in the chapter of
“Lubrication”.

3.2 Rolling Bearing

F-1600HL pump adopts the rolling bearings, which are precision mechanical parts. To
extend the service life, it is required to carry out maintenance on the rolling bearings.
Main bearing is spherical roller bearing. The pinion shaft bearings are cylindrical roller
bearings. There are ribs on both sides to keep the connecting rod on centerline. The
crosshead pin bearings are double row cylindrical roller bearings. Bearing needs no special
adjustment.
The outer and inner ring of all bearings shall match the holes or shafts precisely. The
outer and inner ring of bearings shall be installed in pairs with pair numbers. Therefore,
when re-installation of bearings, it is required to keep the inside and outside rings match
correctly.
It is necessary to replace the defective bearings. Even if only one parts fails, the whole
set (inside and outside rings, rollers and holding rack) must be replaced. The movement
clearance of these bearings is very small, if there is a large clearance, and channel or
abrasion of seat retainer or any defects like pitting or peeling, it indicates that the bearings
fail and it is required to change them as soon as possible.
The coordination of all rolling bearings and journals shall be shrinkage fitting (refer to
each assembly for bearing coordination data). The damaged or worn bearings or seat
retainers can be knocked down from the shaft with a copper bar or a hammer, or taken down
by gas cutting, but be cautious not to damage the shafts. The assembly bearings are usually
heated by oil bath and the temperature shall be lower than 149℃(284°F). The oil and tank

27
must be clean. If directly heat with fire from the lower part of the tank, the bearing outer ring
must be padded up when placing in the oil tank. The time for oil bath of bearings shall be no
more than 3 min.
Generally, do not heat the bearings with flames. If flame must be used under special
circumstances, just experienced welder can operate them. The flame shall be at least
150mm (6") from the bearing, which can be tested with a temperature-test pen. Do not
overheat the bearings. After overheating bearing tempering, the bearing becomes soft.
After the bearings are mounted on the shaft by heating, naturally cool down them at the
location. Do not cool down the bearings with water or other liquids. Fast cooling will make
the inside and outside rings and rollers “heat crack” and rejected.
Do not directly hit the bearing with a hammer. And if required to install the bearings in
place, slightly hit them with a wood hammer.
Generally, the journals and installation holes are coated with lubricants prior to the
bearing installation. The best lubricant is white lead oil, that is, a type of anti-adhesion oil.
After the bearing is taken out from the package, prevent the dusts and foreign matters
into the bearing. Before assembly, it is required to clean the rust oil for packaging. The
cleaning agents must be clean kerosene or other solvents.

3.3 Pinion Shaft Assembly

Fig. 19 Pinion Shaft Assembly

(1) Washer (2) End-cap washer (3) Bearing sleeve (4) End-cap (5) Wear sleeve (6) Bolt

Table 3 Main Matching Sizes of Pinion Assembly mm （inch）

Description Position Coordination

Inner ring and journal A T0.050～T0.109

(T0.002～T0.004)
Outer ring and hole B L0.115～L0.018
（L0.005～L0.001）

28
 Bearing sleeve and Frame hole C L0.203～L0.076
（L0.008～L0.003）
Note: T is the interference and L is the clearance
The gear and shaft as a whole structure, so as long as the assembly of the bearing and
wear sleeve of oil seal is complete (see Figure 19).
The bearing clearance shall be determined by the matching precision of front shaft and
the inner holes of bearing sleeve. When maintenance or repair, ensure that its coordination
shall meet the requirements as set forth in Table 3.
When mounting the pinion assembly to the pump, comply with the following,
1) Ensure that the bearing sleeves washer (1) of the pinion and end cap washer (2) are
intact and correctly installed.
2) The location of the oil sump (7) and the oil return hole shall be aligned when
installation of bearing sleeve (3) and end cap (4).
3) Clear off the burrs, scratches and sump on the outer surface of wear sleeve (5) and
then install the end cap (4) in place. When assembly, be careful. And when the oil seal lip
passes through the shaft keyway, prevent the keyway from being scratched by the sharp
edges. Note that when the oil seal is mounted to the wear sleeve, do not rotate the seal lip at
the edge of the wear sleeve.
4) Tighten the bearing bolt (6) with torque of 194N•m (145lbf•ft)
5) Check the inner and outer rings of the pinion bearing and the rollers and if there is
any abrasion peeling, scratching, or the radial internal clearance exceeding 0.24 mm
(0.0094"), it is recommended to replace with new bearings.

3.4 Crankshaft Assembly

The crankshaft assembly is composed of the crankshaft, bull gear ring, linkage (with
bearings) and main bearings, etc. The clearance between bearings shall be pre-determined
by the precision of the shaft and the holes. For maintenance or repair, be sure to meet the
requirements as set forth in Table 4.
Table 4

Description Postio
Date（mm） Date（inch）
n
(T0.0039～
Inner ring and journal A T0.098～T0.165
T0.0065)
Outer ring and hole B L0.108～0 L0.0043～0
Inner ring and shaft C T0.175～T0.300 T0.0069～T0.0118

29
 Outer ring and hole D T0.112～L0.044 T0.0044～L0.0017
Gear ring and
E T0.026～T0.236 T0.0010～T0.0093
crankshaft
Bearing seat and rack
F L0.050～T0.050 L0.0020～T0.0020
hole
Outer ring and hole G T0.016～T0.083 T0.00063～T0.0033
Inner ring and pin H T0.05～T0.109 T0.0020～T0.0043
Note: T is the interference and L is the clearance.
The assembly of crankshaft follows the methods below (Fig. 20),

Fig.20 Crank Assembly

(1) End cap (2) Bolt (3) Retainer (4) Bolt (5) Bearing Retainer (7) Baffle ring (8) Bolt (8A) Hex Bolts (9)
Main bearing (10) Bearing Sleeve-Right (11) Bearing Sleeve-Left (12) Outer retainer (13) Linkage Bearing
(14) Inner retainer (15) Bolt (16) Main bearing retainer (17) Inner baffle plate (18) Bolt (19) Crosshead
bearing

1) Install the gear ring and check the jumping.

Thoroughly clean the coordination face of the gear ring and the crankshaft flange and
tighten the bolts for gear ring. Tighten the bolt with torque of 2152 N.m（1590lbf•ft）.
Install one set of roller bearings at both ends of the crankshaft and measure the gear
ring face runout with a dial indicator. Due to the impact of the roller bearing clearance, it is

30
required to measure them at the shaft end and the gear face with a dial indicator
synchronously. The actual runout at any point is the difference of two indicators. If the runout
exceeds 0.224mm（0.0088"） , shall take off the bull gear ring and check the reasons of
tolerance.
2) The outer ring and the outer retainer (3) of the linkage bearing (13) are respectively
mounted on three linkages. The outer retainer shall be mounted as such, when the pump is
at the middle stroke, the oil catch-ring shall be at the bottom. Tighten the bearing retainer
ring bolt (4) according to the toque of 75N·m(55lbf•ft), then lock it with wires.
Note: Inner ring, outer ring and roller of the linkage bearing are matched in
groups with the pairs number. Cannot be mixed.
3) Put the outer ring of the crosshead bearing into three small ends of linkages. It is
preferred to cool them down with "dry ice" (CO2), that is, assembly by a deep freezing
method. Under emergency conditions, heat the small linkage heads with flames (do not

exceed 149 ℃（300℉）, which can be measured with a temperature pen. Do not cool down

the linkage head with water.

Note: The inner and outer rings of the crosshead bearings are matched in groups,
with the matching number, cannot be mixed.
4) The inner rings of the crosshead bearing are fitted to the crosshead pin. And mark
them with the corresponding labels (such as 1, 2, 3 or left, right and middle). Before
installation, remove all the burrs and scratches. Tolerances are shown in Table 4, position H.
5) The inner rings of the middle eccentric bearing shall be mounted on the shaft. Mount
the middle linkages in place, and then mount the inner retainer (5), tighten the hex bolt (8A)
with toque of 75N·m (55lbf•ft), then lock it with wires.
6) Install baffle ring (7) in the slot of right eccentric bearing. Install the inner ring at the
eccentric bearing of shaft. After installing linkage, mount the bearing inner retainer (14).
Tighten the bolt (8) with the torque75N·m (55lbf•ft).
7) Mount left eccentric bearing and linkage (Refer to Clause 6 above).
8) Install the main bearing (9) in the bearing sleeve (the serial number (10) is the right
side and the serial number (11) is left). And mount the outer retainer (11). Fastened the bolts
(15) with a torque of 75 N · m (55 lbf • ft).
9) After mounting two main bearing retaining rings (16), install main bearing (9) on both
sides of shaft. Install inner baffle (17) and bolt (18). Tighten the bolt with 75N·m (55lbf•ft).

31
3.5 Mount the Crankshaft Assembly on the Rack

In order to acquire precision fit between main bearing sleeve of F-1600HL pump and
rack hole, please carry out installation according to the following procedures (Refer to
Fig.21).
1) Insert one wood block (See Fig.22) between the small end of linkage and crosshead
guide plate to prevent the guide plate from damage caused by the sliding of linkage.
2) Rotate main bearing sleeve and make its two plane points (in 180 degrees’ position
respectively) parallel to the bolt hole of main bearing. Slowly lay down crankshaft assembly
and put it in place (Reserve clearance between two plane points to allow main bearing bolt
pass through it.).
3) After mounting crankshaft assembly on rack, check the roller of main bearing before
installing main bearing cap (2). Ensure that each row of rollers of two bearings can support
identical loads. The specific measures are as follows, rotate each row of rollers by hand. It is
normal that 4-6 rollers will be seized due to gravity. However, it is not allowed of having the
phenomenon that a certain row of rollers can be rotated. In addition, two sides of outer ring
of floating bearing shall have approximately equal axial clearance. Main bearing cap (2) shall
only be installed after check.

Fig. 20 Installation of Main Bearing Cap

(1) Washer (2) Bearing Cap (3) Lead wire (4) Main bearing bolt
4) Adjust the washer under bearing gland and make it to have pressing thickness of
0.06-0.10mm (0.0024"~0.0040") to acquire pre-tightening force. This pre-tightening force is
acquired according to the appropriate total thickness of gasket. The final thickness of gasket
is determined by the following methods,
a) Put 1.00 mm (0.0394") original washer under bearing gland (at No.1)
b) Put a piece of lead wire (the approximate diameter is 0.8mm) or plastic clearance

32
gauge between outer circle of bearing sleeve and inner circle of bearing gland. It shall be
pressed in the middle position of bearing gland as much as possible.
c) Tighten the main bearing bolt. Torque is shown in Table 5;
d) Dismantle bearing gland to determine the clearance between gland hole and outer
circle of bearing sleeve. It can be obtained by measuring depth at the flattening position of
lead wire or compressed dimension (maximum dimension) of plastic clearance gauge with a
micrometer.
e) Calculate total thickness of washer with this dimension. The calculation methods are
as follows,
Final washer thickness= original washer thickness (it is 1.00mm (0.0394") in this
manual) - flattening thickness of lead wire - (0.06-0.10) mm（0.0024"～0.004"）(amount of
pressing interference).
Example:
1.00mm (original gasket thickness) or 0.040″
- 0.63mm (flattening thickness of lead wire) -0.025″
=0.37mm =0.015″
-0.06-0.10mm (pressing interference) -0.0024-0.0040″
=0.31-0.27mm (total thickness of washer) =0.0126-0.0110″
Note: Because dimensional tolerance of left and right sides after machinery may
not be same, left and right main bearing caps shall be measure respectively. Calculate
washer thickness according to the measured values.
5) Put the washer with final thickness (as mentioned above) under main bearing gland.
Tighten the bolt with the torque shown in Table 5.
6) Check the loads of inner and outer rows of roller on both sides of bearing every time
(as mentioned above) to ensure that each bearing still has equal load.

Table 5 Main Bearing Bolt Torque Value

Torque Thread Wrench Specification

Description
Specification
N·m（lbf.ft） mm（in）
Data 13210（9750） 3”-8UN 92.0（3-5/8″）

3.6 Installation of the Crosshead Guide Plate

1) Clean chamber of the rack and remove oil dirty and sundries on the surface of the

33
guide plate, and remove burr and rough edge and corner.
2) If the old guide plate is used again, check whether the friction surface is worn or
scratched. If yes, please replace them with new plates.
Note: The upper and lower guide plate of F-1600HL pump are different. So they
are not interchangeable. The lower guide places the crosshead on the centerline of
the frame, while the upper guide is machined to provide some clearance between the
crosshead and the guide. Upper guide plate is thinner. There is a big bevel in the rear
position and an oil hole in the middle position of upper guide plate.
3) Assemble the upper and lower guide plates and the tighten torque of its bolt is 257
N•m(190lbf•ft).
4) Check the tightness between the frame and the guide plate, with a 0.05 mm (0.002
in.) feeler gauge not inserted.

3.7 Installation of Crosshead

Crosshead can be installed from the front end (fluid end) or the rear end of guide plate.
See Fig. 22. The following notes shall be followed when installing the crosshead.
1) Completely clear off all dirt, remove the burrs and sharp edges on the surface of the
crosshead circle, crosshead pin hole and the guide plate inner hole, etc., dry the crosshead
pin taper hole to form metal-metal contact.
2) Keep the small end hole (eye) of the linkage at the side hole position of the
crosshead. Pad the linkage with a wood block to keep the crosshead to slide to the location
where the crosshead pin hole is aligned with the small end hole of linkage.

Wood block

Fig. 22 Crosshead Assembly

3) Firstly install the left crosshead and then rotate the crankshaft assembly to keep the
small end of the middle linkage into the middle of the crosshead. At this time, withdraw the

34
right side of linkage hole, take off the fender plate, and push the right crosshead to the front
chamber of the rack, and thus reserve sufficient space for installation of the middle
crosshead, and then install the right crosshead.
Note: If the old crosshead is used again, check whether the slide surface of the
crosshead is worn or scratched. And if necessary, install the crosshead at the
opposite side of the pump, that is, the exchange position of the left and right
crossheads and adjust 180 ° to allow the smooth surface at the bottom of the
crosshead. The middle crosshead can also be adjusted for 180°, at this time, the
crosshead pin shall be installed at the opposite direction. But remember not to insert
the crosshead pin into the taper hole before the crosshead pin baffle is installed.

Fig. 23 Installation of Crosshead Assembly

(1) Fender plate (2) Crosshead pin baffle (3) Bolt (4) Bolt (5) Screw hole (6) Lower guide plate (7)
Rack (8) Drain hole (9) Pipe plug (10) Oil collector (11) Upper guide plate (12) Vent cap (14) Oil level
meter
4) Install the crosshead pin baffle (2) and bolt (3). At this time, rotate the crosshead pin
to align the four bolt holes (4). Install the four bolts and tighten them with hands, as referred
to Fig. 23, the oil sump shall be upward.
Lightly stick the large end of the crosshead pin and make them into the taper hole.
Tighten the baffle bolts (3) and (4) and fix safety wire. Tighten bolt with torque of 290～310
N•m（215～230lbf•ft）.
Use torque wrench to tighten the bolts, don’t exceed the above torque.
Note: The steps for pulling-out of the crosshead pins, take off four baffle bolts (4)
and two of them are screwed into the top wire hole “(5)”. Tighten the two “jack” bolts
until the pins are loosened. Completely remove the crosshead pin plate (2) and take
out the crosshead pin from the holes.
5) Put a long feeler gauge between the upper surface of the crosshead and the guide
plate to check its moving clearance. This clearance shall be 0.62mm ～ 0.75

35
mm(0.024~0.03in). Check the whole surface of the crosshead with a long feeler gauge.
Note: The over-tightening of the crosshead pin baffle bolts (4) will cause the
crosshead arc deformation, increase the opportunities for eccentric wear. At this time,
it is required to loosen the crosshead pins and re-tighten them with a torque wrench
according to the description as above 4).

3.8 Inspection of Crosshead Centering

To make the pistons correctly move in the cylinder liner, the crosshead must have a
movement in a straight line along the horizontal axis of the rack. Check and adjust the
centering of the crosshead according to the following steps,
1) Dismantle the end cover from cylinder liner and piston-nut, piston, spray pipe and
hose clamp from piston rod, while clamp assembly is still used to connect piston rod and
pony rod intently (Fig. 24).

Observation point

Cylinder liner end surface

Cylinder liner bore

Outer ring of piston rod

Fig. 24 Concentricity Measurement Diagram

(1) Cylinder liner (2) Piston rod (3) Clamp assembly (4) Pony rod
2) Horizontal distances from inner bore of cylinder liner to outer ring of piston rod are

36
measured as A and B while vertical dimensions are measure as C and D, coaxially between
the cylinder liner and piston rod is required to be:
Horizontal direction ±0.50 mm (±0.020"), namely｜A-B｜≤1.00 mm (0.0394").
Vertical direction ±0.40 mm (±0.016"), that is ｜C-D｜≤0.80 mm (0.0315").
Two positions required to check, crosshead places rear dead point (nearest to
crankshaft center) and crosshead locates at front dead point as far as possible.
3) If there is sufficient clearance between the upper part of the crosshead and the
upper guide plate, make the above adjustment. Since the angle between linkage, the lower
guide plate has a heavy load, and the force at the back is relatively larger, so the wear and
tear is larger, therefore, the guide plate is well padded.
4) After the concentricity is adjusted, clearance between crossheads of upper guide
plates shall be modified, which shall be 0.62 ～ 0.75 mm(0.0244"~0.0295") for F-1600HL
pumps. The clearance is expected to be reviewed after complete assembly and the
minimum clearance shall be more than 0.50 mm (0.0197"). and it also shall be checked after
long-term use of drilling pump and the maximum clearance shall be less than 1.00 mm
(0.0394").
5) The steel spacer shall be cut sufficiently long to pass the guide plate completely. Cut
into a protruding part at the side and exceed the support of the rack. Refer to the sections (3)
and (4) of “Installation of crosshead guide plate”.

3.9 Maintenance of Fluid end

Over the years, hydraulic cylinder has been regarded as a non-loss part, because it
cannot be punctured by the erosion of liquid like other parts. However, nowadays the
enhancement of pressure of drilling equipment adopted cause occasional occurrence of
damage to hydraulic cylinder. However, regular good maintenance will enable parts at fluid
end to get reasonable service life.
Some major maintenance items are described as below,
1) All valves in one end of outlet port must be opened before operation. Impact load on
the pump will lead to fatigue crack when the valve is closed. And it is possible to have fissure
cracked and the small crack will start the course of Corrosive Fatigue Fracture.
2) Do not close the clutch when the prime mover (diesel engine, motor and its
transmission) runs at high speed, because this will cause impact load that we do not expect,
which is bad for both motive power end and fluid end.

37
 3) Proper maintenance shall be given to the relief valve to ensure it can be opened
when the adjusted nominal pressure is exceeded, and the adjusted pressure is related to the
dimension of the cylinder liner, and see introduction in Shear Pin Relief valve for details.
4) When serious hydraulic impact happens, do not use the pump for a long time.
Perform proper maintenance of fluid end. When the pump is not in use or cease
operation for more than 10 days, it is suggested to dismantle some parts such as piston,
piston rod, cylinder liner from the fluid end, rinse the power end thoroughly with water, wipe
up after washing, and then coat the machined surfaces such as sealing end, cylinder liner
flange screw, valve bonnet screw, valve seat with protective grease. Of course, the parts
removed from the pump including cylinder liner, piston shall also be taken protective
treatment. Doing in this way not only extends the service life of the fluid end but also protects
wearing parts removed from the pump so that they are in good condition and can be
installed for use when the pump restarts.
The fluid end assembly of triplex pump consists of three forged hydraulic cylinders,
cylinder liner, valve bonnet and cylinder head, suction pipe and discharge pipe.

3.9.1 Hydraulic cylinder

For the structure of suction, discharge hydraulic cylinder see Fig. 25. And the size see
Table 6.
The fluid end consists of three pairs of interchangeable suction and discharge cylinders.
The discharge cylinders are connected to the metal by studs with power-end frame, through
the holes of the power end frame and the wear plate to ensure that the power end and
discharge cylinder alignment. In the same way, the suction and discharge hydraulic cylinder
are positioned through the metal boss of the suction hydraulic cylinder and connected by
bolts. For accurate alignment, groove marks, burrs and dirt on the combination surface of
the rack hole and hydraulic cylinder, wear resistant plate must be removed, otherwise
“warping” or deflection will be produced after the three are connected.

38
 Fig. 25 Hydraulic Cylinder
(1) Discharge hydraulic cylinder (2) Bolt (3) Suction pipe (4) O-ring (5) Bolt (6)
Discharge pipe (7) O-ring (8) Bolt (9) Suction hydraulic cylinder (10) Bolt
Table 6
Position Dimensions(mm)
A 368.275-368.325
B 170.063-170
C 143.25-143
D 187.46-187.33
E 168.66-168.53
F 158.8-158.67
G 148.02-147.82
H 158.8-158.67
K 148.02-147.82
L 168.66-168.53
M 187.46-187.33
N 33.9-33.7
P 15.85-15.75
Q 12.8-12.6
S 12.8-12.6
Hole：140.000～140.063
T
Shaft：139.894～139.957

3.9.2 Suction pipe

Suction pipe (3) connects each hydraulic cylinder (9) by bolts, seal the combination
surface of flange with O-ring (4). Rinse thoroughly O-ring groove and the O-ring seal at the
bottom of hydraulic cylinder, put in the O-ring before installing the suction pip, flange must be
a metal-to-metal connection to ensure the seal of O-ring. Therefore, any nicking groove or

39
punctured part on the sealing surface must be repaired before installation. See section (3.10)
Repair Welding and Repair in this manual for repair procedures.
Before tighten discharge pipe nuts (5), first screw bolts in the three hydraulic cylinder
(do not tighten when it looses), and then tighten the nuts connecting pump head with the
rack according to the torque value shown in Table 7 with torque wrench. (See the description
below)

3.9.3 Discharge pipe

Tighten the bolt (8) of the exhaust pipe on every hydraulic cylinder and use O-ring (7) to
seal on connecting flange. Clean the O-ring recess and adjoining plane on the hydraulic
cylinder thoroughly before the installation of the exhaust pipe. It must be metal-to-metal
connection to press O-ring. So any notch, groove and puncture on the sealing face shall be
renovated before the installation (See repair welding and repair section of this manual for
details).
Before tighten discharge pipe nuts (5), first screw bolts in the three hydraulic cylinder
(do not tighten when it looses), and then tighten the nuts connecting pump head with the
rack according to the torque value shown in Table 7 with torque wrench.

3.9.4 Suction hydraulic cylinder

The replaceable suction hydraulic cylinder (9) is tightened on the discharge hydraulic
cylinder (1) by bolts, and the suction hydraulic cylinder must form a metal to metal
connection, in order to ensure the axis on the end face and hydraulic cylinder vertical.
Therefore, make sure that the burrs, salient points and foreign bodies on the joint surface
are removed before installation. Tightening torques of nuts (10) are shown in Table 7.

Table 7 Tightening Torque

Position No. in the picture TorqueN•m Torque lbf•ft
With the rack 2 2152 1590
Suction pipe 5 195 145
Discharge pipe 8 2786 2055
Suction hydraulic cylinder 10 3538 2610

3.9.5 Valve seat disassembly

The disassembly tools and method used for the suction and discharge hydraulic
cylinder are consistent.
First, remove all parts such as the bonnet, valve spring, valve body assembly above the
valve seat, put the hook and lead screw in the attachment tools into the valve seat hole, and

40
shake the lead screw to fit the hook and valve seat, as shown in Fig. 26 (a);
Then, put other parts such as the supporting seat, cylinder block, cylinder cover, etc. in
the hydraulic valve lifter on the upper part of the hydraulic cylinder successively, and tighten
the triangular claw, as shown in Fig. 26 (b);
For the sake of safety, it is better to hoop the supporting seat, cylinder block and
cylinder cover, etc. on another hydraulic cylinder with a hemp rope or nylon sling, in order to
avoid the valve seat flying and hurting people when it is pulled out, as shown in Fig. 26 (c);
Finally, connect the hose on the hand operated hydraulic pump to the oil cylinder joint,
as shown in Fig. 26 (d). Note that install the pressure gauge near the side of the manual
pump for easy observation. Press the manual hydraulic pump on the ground until the valve
seat is pulled out.

Screw Triangular claw

Support Oil cylinder cover

Valve seat Cylinder seat

Hook

Hemp rope or nylon sling

Connecting hose of hand pump

Fig. 25 Disassembly Diagram of Valve Seat

3.10 Repair Welding and Repair

When it is needed to repair normally worn or damaged cylinder hole, it shall be welded
according to the following welding specifications. Then, welded hole shall be machined. The
dimension of machined hole shall comply with the data specified in Table 6. Furthermore, the

41
shoulder of hole (installing cylinder liner, bonnet and cylinder head, etc.) shall make an angle
of 90 degrees with the axis of hole in all conditions.
3.10.1 Welding procedures
Welding is usually divided into two types: (A) "punctured"(include normally worn and
punctured), (B) crack. The basic information of repair is listed as below.
A Punctured (include normally worn and punctured)
Clean area to be given repair welding: clean welding zone by gouging or grinding
method to expose the medal.
Procedures for repair welding of puncture are as follows,
a) Welder shall observe requirements of safety, qualification and technology related
welding process.
b) Adopt shielded metal arc welding method, welding material shall be electrode
conform to AWS A5.1 E7018 or GB/T5117 E5018.
c) Using of welding material shall execute the requirements of product instruction of
manufacturer.
d) The range of preheating of repair welding area shall be at least 75mm(3″) at all
directions, heating temperature is not less than 200℃ (392℉) , layers temperature is 200°～
350℃ (392℉～662℉) .
e) After one course welding finished, shall clean carefully. When confirm there is no
defect, weld next. After welding completed, heat welding area and surrounds to 350℃
(662℉) and keep 10 minutes, then cool naturally.
B Crack
Clean of repair welding area: remove all cracks by mechanical means. If gas cutting is
anticipated to use for removal of crack, it only leads to speed of crack propagation more than
metal ablating velocity, so the method is not advised.
Preheating: The purpose of preheating is to enlarge the welding zone so that the
cooling of preheating zone is more consistent with that of weld repairing area in the cooling
process. Eliminating hot cracking when welding can prevent forming hard points between
solder and basic metal, obviously, this kind of hard point is the position easy to cause fatigue
crack.
Procedures for repair welding of crack are identical with that for above-mentioned
puncture.

42
3.11 Repair of Bonnet Hole

When repairing erosive (punctured) of bonnet hole, the most important thing is to keep
the plane of the valve bonnet seat completely flat and at the angle of 90 ° with the axis of the
thread when turning or grinding, as shown in Fig. 27. Valve bonnet retainer ① mounted in
the sink hole at the top of the valve bonnet hole form a metal-to-metal connection. Obviously,
high points formed on the valve bonnet during any welding or low points formed due to
over-grinding on the welding point will form clearance between the bottom of valve bonnet
and the plane of hydraulic cylinder, obstructing ring will be extruded or punctured under
pressure. High or low points will also form a "tilting" on the valve bonnet, since the two
thread axises are not perpendicular, its consequence is to lead to serious damage to screw
thread.

Form a
metal-to-met
al connection

Fig. 27 Bonnet Repair

3.12 Replacement of Bladder

Replacement of bladder can be carried out in accordance with the following procedures
(refer to Fig. 12):
1) Confirm that the system has been decompressed completely (refer to 1.7 Pulsation
dampener assembly).
2) Dismantle the cover (2), you can use three dismantle screw to push it out, if stud is
screwed out from the Enclosure when disassembling, first remove the nut (R1), then rinse
the bolt and screw, then screwed in the stud (with a special stud wrench or tighten two nuts
with a common wrench), with tighten torque of 1600N.m(1180lbf•ft).
3) Remove the bladder.

43
 Insert a bald bar without burrs, edges and corners from the middle of the bladder and
Enclosure, flatten the bladder and take it out from the top.
4) Check if the bladder is damaged. If the bladder is damaged due to be punctured,
inside the Enclosure and then check whether there is lump or foreign substance in the
Enclosure and damage-related position resulting in the damage, factors caused the damage
must be eliminated.
5) Intall a new bladder.
Flatten the bladder and roll it into a spiral shape so that it can be put in from the opening
on the top of the pulsation dampener, then stretch it and adjust the bladder to make it touch
with the Enclosure, finally push obstructing ring on the neck of the bladder to the opening of
the Enclosure and apply lubricating grease to inner side of the neck.
Bend the balance disc and put it into the bladder, compress with pressing plate, spring
washer and bolts.
6) Install top cover (2).
7) Tighten nut (R1) with tighten torque of 4418N.m(3260lbf.ft)
8) Inflate according to the methods described in section 1.7.2.

3.13 Approximate Weight of Each Assembly

Pinion Shaft Crankshaft Crosshead Rear Suction Connection part
Name Crosshead
Assembly Assembly Pin & Baffle Cover Manifold of 1/3 fluid end
Weight: kg 1319 7534 200 92 245 366 1965

Note: The 1/3 connection part of fluid end refers to one pump head (including suction
and discharge hydraulic cylinder, etc.). Triplex pump has three pump heads in total. Each
pump head can be regarded as one part.

44
 4 Maintenance and Inspection Point
Proper and timely maintenance of drilling pump is a necessary measure to ensure
normal operation of the pump and extend its service life, which shall be paid attention at the
time of using any of the pumps.

4.1 Daily Maintenance

(1) Check oil level at power end at least once a day when oil surface is stable. If chain
drive is used, shall also check oil level of chain box.
(2) Check the oil pump pressure gauge changes. If the pressure is found to be very
small (less than 0.035MPa) or no pressure, shall promptly check the suction and discharge
filter whether the phenomenon of blocking.
(3) Check whether the work of the suction dampener is normal.
(4) Check the exhaust dampener inflation pressure, whether to meet the operating
conditions.
(5) Check the reliability of the safety valve, if necessary, shall be replaced.
(6) Observe the cylinder and piston working condition. There is a small amount of mud
dragged out by the piston, is the normal situation. If the occurrence of a thorny situation, the
timely replacement of the piston and check the cylinder liner hole wear, such as wear and
tear is larger, the cylinder shall also be replaced.
(7) Check the front chamber, if there is a large number of mud, oil precipitation, shall be
cleaned.
(8) Check the water tank of spray pump, water shall be added to the insufficiency, and
pollution shall be replaced, but also need to clean the tank.
(9) Loosen the piston rod clamp every day to check whether the clamp cone and the
piston rod, the pony rod is clean, and the piston rod is rotated by a quarter turn. In this way,
the wear surface of the piston can be evenly distributed to extend the service life of the
piston and the cylinder liner.
(10) Before installing the cylinder head and bonnet, coat grease to the surface of the
thread. Check every 4 hours whether there is a loose phenomenon.
(11) Often observe the bonnet seal, cylinder seal (including wear between the disk and
the cylinder seal) alarm hole, if the mud discharge, it shall promptly replace the
corresponding ring.

45
4.2 Weekly Maintenance

(1) Remove the bonnet and liner once a week, remove the sludge and clean it. Coat
extreme pressure (composite) lithium grease.
(2) Check the inner sleeve of the stem guide, if it has been obviously worn (the gap
between the valve guide rod and the guide is more than 3mm) shall be replaced so as not to
damage the guide to the steering effect.
(3) Check service condition of valve and valve seat, replace seriously worn or punctured
valve, valve rubber and valve seat (shall also pay attention to replace valve at the same time
of replacing valve seat), check valve spring, replace broken spring or spring losing elasticity.
(4) Check lock nut of piston, in case of corrosion or damage, it shall be replaced
(because the O-ring inside the nut has lost its ability to lock in general after the nut has been
fastened three times).
(5) Discharge water from the plug of sewage flange once until oil can be seen.
(6) Check and clean strainer in the pipeline of grease pump once.

4.3 Monthly Maintenance

1) Check all studs and nuts at fluid end, such as flange nuts on cylinder cover, nuts
connecting hydraulic cylinder and the rack, coupling bolts and nuts on suction manifold and
exhaust manifold, etc. If there is looseness, tighten according to the stipulated torque values.
2) Check sealing ring in the packing box of pony rod, replace it if it has worn, usually
replace at least once every three months, shall pay attention to direction of oil seal upon
replacement. (inward main seal lip)
3) Dismantle and clean filter drum installed in the discharge screen.
4) Replace dirty oil in oil sump at motive power end and crosshead sedimentation oil
sump once every six months, then clean up the oil sumps at the same time.

4.4 Yearly Maintenance

(1) Check the crosshead and guide surface wear, check the cross head guide is loose,
crosshead operation gap is in line with the requirements. Spacer can be added under the
guide plate to adjust the clearance. Can also rotate the crosshead at 180 ° and use it (for
easy operation, you can change the position of the crosshead).
Crosshead shall be discarded when the outer surface of crosshead is worn more than
2mm （0.079"）or 3mm (0.118") marks are more than 5 place or taper hole reformatted;

46
 Guide plate shall be discarded when guide plate has crack, or inner surface of guide
plate is worn more than 2mm （0.079"）or 3mm (0.118") marks are more than 5 places;
(2) It is recommended to carry out a comprehensive inspection on the pump once every
two years or three years. Check if main bearing, linkage bearing, crosshead bearing, input
shaft bearing are worn or damaged, if cannot continue to be used, shall replace by a new
one.
The discard clearance of each bearing: main bearing 0.40 mm (0.0157"); Input shaft
bearing 0.24(0.0094") mm; crosshead bearing 0.35 mm (0.0138"); eccentric bearing 0.50
mm (0.0197").
(3) Check wear condition of gear pair, if badly worn, shall make U-turn installation for
driven shaft and driving shaft simultaneously to make use of tooth surface without wear.
Gear shall be discarded when has crack, broken tooth and open pitting corrosion on
gear surface of more than 2mm（0.079"）.
For easier reference, above maintenance check points are now shown in Table 8 and
Fig. 28, please execute carefully.

4.5 Other Matters to be Paid Attention during the Maintenance

(1) Before mounting the clamp of pony rod and piston rod, the tapered surface must be
wiped clean.
(2) When replacing cylinder liner, sealing ring of the liner must be replaced together.
(3) After the pump is stopped in winter or temporary stoppage of the pump for more than
ten days, must discharge mud in valve chamber and cylinder liner and rinse them
completely.
(4) All inspection windows and holes of pump shall be covered in a right way to prevent
dust from mixing into lubricating oil inside.
(5) Discharge pulsation dampener can only be filled with nitrogen or air, it is prohibited
to fill with inflammable or explosive gases such as oxygen, hydrogen and so on.

47
Fig. 28 Routine Maintenance

48
 Table 8 Routine Maintenance List
Period No. Routine Maintenance Contents
1 Stop the pump to check oil level, if the oil level is too low, increase it to
Daily
the desired height
2 If the reading of lubrication pump pressure gauge is normal, if pressure
Daily
is too low, check the cause timely
Daily 3 Check that the air dampener is working properly
4 If cooling lubricant in water tank of spray pump is in shortage, fill it up; if
Daily
goes bad, replace it.
5 Check the cylinder liner of the rack, if there are a large number of slurry
Daily
or oil deposits, shall clean up
6 Observe if the seals of piston and cylinder liner has leakage, make
Daily
replacement if serious
7 Observe if piston and cylinder liner has leakage, make replacement if
Daily
serious
8 Loosen the clamp on piston rod once a day, tighten the clamp after turn
Daily
the rod by a quarter of a circle
9 Check whether the bonnet is loose once every 4 hours, and often coat
Daily
with lubricating grease on the screw thread.
Daily 10 Check if relief valve is reliable
11 Check if pre-charge pressure in discharge pulsation dampener is
Daily
normal n when stopping the pump
12 Observe indicator hole, if there are slurry discharged, replace the
corresponding O-ring timely
Daily
Judge whether the pump valve operates normally by means of hearing,
and check it if not.
13 Remove the bonnet, clean the mud, coated with molybdenum disulfide
Weekly
composite calcium-based grease
Weekly 14 Check the inner sleeve of valve stem guider, if the wear and tear
exceeds the requirement, it is needed to be replaced
Weekly 15 Check suction and discharge valve, valve seat, valve rubber and valve
springs. Make replacement if there is any damage

49
Weekly 16 Check if piston locknut has corrosion or damage. If so, make
replacement (generally can be used three times)
Weekly 17 Check if filter screen in lubrication system is clogged. If so, it shall be
cleaned up
Weekly 18 Unscrew plug from sewage flange to discharge dirt and water
accumulated in the oil pool
Monthly 19 Check if bolts and nuts at fluid end loose or damage, if any, tighten or
replace as required
Monthly 20 Check O-ring in the packing box, replace it if worn, make replacement at
least once every three months
Monthly 21 Check whether the filter in the discharge pipe is blocked by sundries
and so on, and clean it if it is blocked.
Monthly 22 Replace dirty oil in oil pool of power end and cross head sedimentation
oil tank every six months and rinse completely
Yearly 23 Check the wear condition of cross head and surface of guide plate, if
necessary, can rotate the cross head 180 ° for reuse
Yearly 24 Check if guide plate has looseness, if cross head clearance meets the
requirements, if not, they shall be checked and regulated
Yearly 25 Check the pinion shaft, crankshaft tooth surface wear and tear, if
necessary, use the surface
Yearly 26 Check if pinion shaft assembly, crankshaft assembly are intact,
measures shall be taken if there is anomaly
Yearly 27 Check if bearing at the power end has damage, if so, make replacement
Yearly 28 Check seal condition of back cover, crankshaft cover and other parts, if
fail to achieve a good seal effect, make replacement

50
 5 Possible Failures and Solutions
If failure occurs when drilling pump is in operation, shall find out the cause and clear the
failure timely. Otherwise, it may cause damage to the parts and affect the normal drilling
work.

5.1 Failure of Fluid end

Table 9 Troubleshooting of Fluid end

Failures Causes Troubleshooting
1.Tighten the flange bolts of
1.Suction manifold are not
1. The value of pressure gauge suction manifold or replace
sealed tightly, resulting in the
drops, discharge amount reduces or the gasket.
entering of air into the pump
no discharge of mud. 2. Stop the pump to clear
2.Suction filter is blocked.
debris off the suction filter.
1. Replace damaged piston,
2. The liquid discharge is uneven
1.One of the pistons or valves check if pump valve is
with suddenly large or suddenly
is badly worn or damaged. damaged or stuck.
small impact. Amplitude of swing of
2. Air enters into the pump 2. Check if suction manifold
pressure gauge pointer is too big.
cylinder. and valve bonnet are sealed
Suction manifold have whirs.
tightly.
1. Tighten the piston nut.
1. Piston nut loose.
2. Tighten the cylinder liner
3. There are drastic beats at the 2. Cylinder liner gland loose.
gland.
cylinder liner. 3. Poor suction cause water
3. Check the cause for poor
hammer.
suction.
4. Indicator holes at valve bonnet, 1. Valve bonnet is not
1.Tighten the valve bonnet.
cylinder cover and cylinder liner seal tightened.
2. Replace the O-ring.
have mud leakage. 2. O-ring is damaged.
1. Gas-filling joint is blocked.
1.Remove debris off the joint.
5. Discharge pulsation dampener 2. Capsules in the pulsation
2. Replace the capsules.
cannot be filled in the gas or the air dampener have been broken.
3. Repair or replace needle
leaks soon after filled. 3. Needle valve is not sealed
valve.
tightly.
Discharge filter cartridge is Remove the cartridge for
6. Diesel engine has heavy load.
blocked. clearing debris away.

51
5.2 Failure of Power End

Table 10 Troubleshooting of Power End

Failure Cause Troubleshooting

1. Temperature of bearing 1. The oil pipe or oil hole is blocked 1. Clean the oil pipe and oil hole
is high 2. The oil is too dirty or deteriorated 2. Replace the oil
3. The rolling bearing is worn or 3. Repair or replace bearings
damaged 4. Make the amount of oil
4. Too much or too little oil appropriate
2. The power end with 1. The crosshead guide plate has been 1. Adjust the gap or replace the
percussion sound seriously worn worn guide plate
2. The bearing is worn 2. Replace the bearing
3. The guide plate is loose 3. Tighten the bolts of guide plate
4. The fluid end with water hammer 4. Improve the suction
phenomenon performance

3. Oil leakage at the pony 1. The seals are damaged 1. Replace the seals, and it is
rod packing box 2. The lower guide plate is seriously recommended to replace them
worn every three months
2. Examine and repair the
crosshead guide plate

5.3 In addition to the above possible failures

Such as the discovery of other anomalies, due to the location of the failure to find the
reasons carefully, until the cause identified and excluded after the drilling pump can be
normal operation.

52
 6 Storage Precautions
When drilling pump doesn’t use or shut down for a long time, protect and store
according to following requirements:

6.1 Protection of Fluid end

6.1.1 Drilling fluid of fluid end (inclusive of pulsation dampener and relief valve) shall be
drained before stored and wash with clean water, and remove dirty of all parts and
components of fluid end and cylinder liner cavity. Take out parts, such as valve body, valve
spring, valve guide, cylinder liner, piston, piston rod, bonnet, and cylinder cover, plug,
hydraulic liner gland, etc. Dry these parts and inner cavity of cylinder in open air and wipe
cleanly, and then let finished surface of them are coated with rust-preventative lubricating oil
for bearings with dynamic viscosity (40℃) no less than 100 mm2/s. And connecting threads
of bonnet and cylinder, and connecting threads of flange of cylinder liner shall be coated with
lithium base grease. All these parts shall be put in cylinder successively and tighten up
bonnet, cylinder liner gland.
6.1.2 For discharge screen, pressure gauge, discharge five-way assembly or connector
of relief valve, mutual mating surface and ring groove of sealing gasket shall be provided
with rust-preventative lubricating oil for bearings with dynamic viscosity (40℃) no less than
100 mm2/s.
6.1.3 Faces of discharge flange on both side of fluid end and ring groove of sealing
gasket shall be provided with rust-preventative lubricating oil for bearings with dynamic
viscosity (40℃) no less than 100 mm2/s.
6.1.4 Suction inlet and outlet port shall be blocked with blind plate.
6.1.5 Exhaust pulsation dampener completely.

6.2 Protection of Power End

6.2.1 Drain water tank of spraying pump entirely and keep it dry.
6.2.2 Discharge engine oil at the bottom of gear case of power end.
6.2.3 Open sewage flange for draining sedimentation basin.
6.2.4 Bearing, crosshead, guide plate, gear, pony rod on power end shall be coated with
rust-preventative lubricating oil for bearings with dynamic viscosity (40℃) no less than 100

53
mm2/s to form a coating of protective oil film.
6.2.5 Mount piston rod and pony rod and coat exposed parts of the pony rod with
rust-preventative lubricating oil for bearings with dynamic viscosity (40℃) no less than 100
mm2/s, and wrap up with oil paper.
6.2.6 Cover, rear cover, eyehole cover of crosshead shall be sealed tightly.
6.2.7 Dismantle air filter on upper part of rack and block with screwed plug tightly.
6.2.8 Shaft extension of pinion shall be coated with rust-preventative lubricating oil for
bearings with dynamic viscosity (40℃) no less than 100 mm2/s or lubricating grease and
protective measures.

6.3 Storage

The drilling pump shall be stored at dry, clean, less dust and vibration-free site. It shall
be placed on flat position. It is advisable to store at storeroom and cover it with waterproof
cloth for outdoor storage. Riser vent of the waterproof cloth shall be opened after rain to dry
vapors within it, and then cover the riser vent tightly. If drainage of storage site has been
blocked, the pump shall be raised with cushion block, the position of cushion block is shown
as Fig. 29. The distance from ground shall be no less than 100 mm (4") to avoid soaking and
rusting.

Fig. 29 Schematic Diagram of Position of Cushion Block

Surrounding and top of drilling pump shall be protected sufficiently to avoid damages
arising from other articles’ falling or collision. Accessory case of the drilling pump is filled up

54
with rubber articles, so it shall be stored at dry environment to avoid contact with sun directly,
fluid and ozone, as well as radioactive substance.

55
 7 Ordering Information

7.1 Single pump range

Single pump includes: pump body, spray pump, pulsation dampener, relief valve,
auxiliary tools and disposable rubber seal for replacement.
Single pump does not include pulley, skid.
Spray pump adopts motor drive, if need shaft head belt drive spray pump, users shall
specify when ordering.
Lubrication oil pump at drive side adopts built-in structure. If users require other drive
types, it needs to specify them.
When users have not special requirements, pumps will be assembled with φ
260-cylinder liner piston when out of factory.

7.2 Metric and imperial products

F series pump metric system, the British two types, by the user choice.
Metric pumps are made of metric threads. British pump with US-made thread.

56
 8 Use of Special Tools
8.1 Ordinary Valve Seat Extractor - Hook Type (When using ordinary valve
assembly)

(1) Hook assembly AH130101-16060200 (2) Screw AH160201-090101

8.2 Hoisting Tools of Cylinder Liner AH130101-160100

8.3 Dismantlement Frame of Piston Nut AH130101-161400

57
8.4 Conversion coupling (AH100101-2115)
Conversion coupling used for dismantling connection bolts of pony rod and crosshead.

8.5 Bolt M24×220（AH130101-1611）

Used for dismantling the wear plate

8.6 Sleeve-- Tool for Dismantling Nuts of Fluid end

8.6.1 Sleeve 3 5/8（AH130101-1602）

8.6.2 Sleeve 1 1/2（AH130101-1603）

58
8.6.3 Long Sleeve（AH130101-161000）

8.6.4 Sleeve 2 3/8（AH100101-2108）

8.6.5 Sleeve 2"（AH100101-2109）

8.7 Conversion adapter (Used to transition the sleeve from 19.05 to 25.4)

8.8 Conversion adapter （ Use to remove the hexagon screw of the

discharge flange）

59
8.9Cylinder head rod AH100101-210100
For disassembly cylinder head, bonnet.

8.10 Gas-filling Hose of Pulsation dampener AH100101-210700

60
 9 Guide for Selection of Lubricating Oil
Lubricating Position and Ambient Recommended Oil Products
Oil Specifications
Description Temperature Kunlun Changcheng Mobil
AGMA Mild EP # 7 * KG460 Heavy-duty
+10oC～+68oC L-CKD 460 Industrial
L-CKD 460 Industrial Gear Oil Mobilgear 634
Mud pump gear box Enclosed Gear Oil
Enclosed Gear Oil (GB5903) CKD460 Gear Oil
(Note: the oil contains
AGMA Mild EP # 6 * KG320 Heavy-duty
antirust and -7oC～+38oC L-CKD 320 Industrial
L-CKD 320 Industrial Gear Oil Mobilgear 632
anticorrosion, Enclosed Gear Oil
Enclosed Gear Oil (GB5903) CKD 320 Gear Oil
foam-inhibiting and
AGMA Mild EP #2 *
parathion-based -29oC～+16oC KG68 Heavy-duty AP-L 68 Industrial Gear
L-CKD 68 Industrial Mobilgear 626
extreme pressure Gear Oil Oil
Enclosed Gear Oil (GB5903)
wear-resisting
L-CKT 220 Synthetic L-CKT 220 Synthetic Mobilgear
additives) KG/S220 Heavy-duty
-40oC～+27oC Extreme Pressure Industrial Heavy-duty Industrial SHC
Gear Oil
Gear Oil Gear Oil 220
L-CKT 150 Synthetic L-CKT 150 Synthetic
Grease-lubricated -50oC～+16oC KG/S150 Heavy-duty Mobilgear
Extreme Pressure Industrial Heavy-duty Industrial
bearings (for spray Gear Oil SHC150
Gear Oil Gear Oil
pump, drive shaft,
Above 0oC NLGI 2 Extreme Pressure 2# Extreme Pressure 2# Extreme Pressure
cardan shaft) Bonnet Mobilux EP 2
Lithium Base Grease Lithium Base Grease Lithium Base Grease
thread, and discharge
Below 0oC NLGI 1 Extreme Pressure 1# Extreme Pressure 1# Extreme Pressure
filter cover thread, etc. Mobilux EP 1
Lithium Base Grease Lithium Base Grease Lithium Base Grease

61
10 List of Parts of F-1600HL Drilling Pump

Drawings Description Drawing No. or Part No.

F-1600HL General Assembly Drawing AH160201-00
F-1600HL Fluid End Assembly AH160201-0100
F-1600HL Piston AH160203-010500
F-1600HL Cylinder Liner AH160203-010600
F-1600HL Valve Assembly（API 7） AH160201-011900B1
F-1600HL Discharge Cylinder Assembly AH160201-010400
F-1600HL Suction Pipeline AH160201-010500B1
F-1600HL Suction Dampener AH000005-0800
F-1600HL 5″Auxiliary Pipeline AH160201-0200B1
F-1600HL Filter Drum Assembly AH160201-020200B1
F-1600HL Connection flange assembly AH160201-020400B1
F-1600HL Crankshaft Assembly AH160102-0100
F-1600HL End cover of main bearing AH130101-020100B2
F-1600HL Lubrication Assembly of Power End AH130101-0600B3
F-1600HL Safety Valve Assembly AH100101-061400
F-1600HL Oil Pressure Display Device AH050101-060200B1
F-1600HL Gear Assembly of Oil Pump AH100101-061200
F-1600HL Pinion Shaft Assembly AH160101-0200
F-1600HL Hoisting AH130101-1000
F-1600HL Spray Pump Assembly AH160201-1200B1
F-1600HL Crosshead Assembly AH130101-0400
F-1600HL JA-3H Shear Pin Safety Valve AH000006-0300
JAF-3×52 Flange Type Shear Pin Safety
F-1600HL AH000006-1000
Valve
F-1600HL WY75-52 Pulsation Dampener AK755201-00
F-1600HL Shell Assembly AK755201-0100
F-1600HL Spare Parts of Mud Pump AH160201-0800
F-1600HL Tools of Mud Pump AH160201-0900
F-1600HL Hydraulic Valve Extractor AH160201-090100
Inflatable Hose of Pulsation Dampener
F-1600HL AH100101-210700
assembly

62
10.2.1 General Assembly Drawing of F-1600HL Drilling Pump
(AH160201-00)

63
No. Drawing No. Name Qty.
1 AH160201-0100 Fluid End Assembly 1
2 AH160201-0200B1 5" Auxiliary Pipeline（52MPa） 1
3 AH160201-0300 Support 1
4 AH160201-0400 Skid 1
5 AH160201-05B2 Nameplate(English) 2
6 AH160201-0600B3 Safety Valve Connecting Pipe 1
7 AH130101-19 Adjustable Spacer 1
8 AH130101-0100 Rack Assembly 1
9 AH160101-0100 Crankshaft Assembly 1
10 AH100101-1400 Oil Level Gauge Assembly 2
11 AH130101-0600B3 Lubrication Assembly of Power End 1
12 AH160101-0200 Pinion Shaft Assembly 1
13 AH160201-07B1 Crosshead Hole Cover 1
14 AH130101-15 Gasket 2
15 AH160201-1200B1 Spray Pump Assembly 1
16 AH130101-1800 Cover Assembly 1
17 AH130101-0400 Crosshead Assembly 3
18 AH130101-1000 Hoisting 1
19 AH130101-1100 Hoisting Rack 1
20 512605520020600000 Air Filter C-M60X2 1
21 AH100101-09B1 Seals Ring 2
22 AH130101-1200 Cover 1
23 AH130101-13 Gasket 1
24 AH100101-13 Mud Pump Indicator 2
25 AH100101-1500 Drain Cover (Ⅲ) 2
26 AH100101-16 Seals Ring 2
27 AK755201-00 WY-75-52 Pulsation Dampener (Imperial) 1
JAF-3×52 Flange Type Shear Pin Safety
28 AH000006-1000 1
Valve
29 420201011124110060 Bolts M24×110-8.8-Zn.D 8

30 420402016240400000 Nuts M24-8-Zn.D 8

31 420503016241600000 Standard Spring Washer 24-Zn.D 8

32 420503016161600000 Standard Spring Washer 16-Zn.D 4
33 420201011116060060 Bolts M16×60-8.8-Zn.D 4
34 420402016160400000 Nuts M16-8-Zn.D 4
35 420101063104000800 Stainless cross slot screws M4×8 30
36 420201011112025060 Bolts M12×25-8.8-Zn.D 30
37 420201011112035060 Bolts M12×35-8.8-Zn.D 8
38 420201011116040060 Bolts M16×40-8.8-Zn.D 28

64
39 420501016160300000 Flat Washers A 16-200HV-Zn.D 28
40 420402016270400000 Nuts M27-8-Zn.D 8
41 420201011127090060 Bolts M27×90-8.8-Zn.D 8
42 420503016271600000 Standard Spring Washer 27-Zn.D 8
43 AH160201-0001 Foam Rubber Sheet t 40×8×5800 1
44 420501016120300000 Flat Washers A 12-200HV-Zn.D 38
45 T508-6002 Rim BX152 1
46 AH160201-07B2 Crosshead Hole Cover 1

Dual-scale Seismic Pressure Gauge

47 380207302701611501 1
YTN150-F200 70MPa

48 T503-1007 Stud 1 M30×3×240 12

49 T507-2001 Nuts 1 M30×3 24

50 T508-6001 Rim BX169 2
51 T503-1011 Stud 1 M27×190 8
52 T507-2005 Nuts M 27 16
53 170506010100243000 Anaerobic adhesive - Loctite 243 1
54 AH160201-0800 Spare Parts of Mud Pump 1
55 AH160201-0900 Tools of Mud Pump 1
56 T508-6006 Rim BX154 1
57 AH130101-2000 Spindle Guard 2
58 T515-2005 Mud pump warning sign 2
59 T515-2013 Drainage Instructions Nameplate 2
60 AH220201-11 Cover 2
61 AH220201-12 Gasket 2

65
10.2.2 Fluid End Assembly AH160201-0100

66
No. Drawing No. Description Qty.
1 AH160201-010400 Discharge Hydraulic Cylinder Assembly 3
2 AH160201-010500B1 Suction Pipeline 1
3 AH160201-0107B2 Wear Plateφ190 3
4 AH160201-0108 Discharge Pipeline 1
5 AH160201-0110B1 Suction Hydraulic Cylinder 3
6 AH160201-011100 Piston 3
7 AH160201-0113 Hydraulic Cylinder Seals 3
8 AH160201-0114 Discharge Pipe Seals 3
9 AH160201-0115 Wear Plate Seals 3
10 AH160201-0116B4 Cylinder Liner Seals (φ170) 3
11 AH160201-0116B5 Cylinder Liner Seals (φ185) 3
12 AH160201-0116B6 Cylinder Liner Seals (φ220) 3
13 AH160201-011800 Cylinder Liner 3
14 AH130101-0518 Cylinder Liner Locking Ring 3
15 AH160201-0122B1 Bonnet Seals 6
16 530301012000070015 O-Ring 200×7.00FPM 3
17 AH100101-0529 Valve Spring 6
18 AH160201-011900B1 Valve Assembly（API 7） 6
19 530301011850070015 O-Ring 185×7.00FPM 3
20 AH130101-051900 Clamp Assembly 3
21 AH130101-0520 Cylinder Liner End-cover 3
22 AH130101-0515B1 Cylinder Liner Pressure Cover 3
23 AH130101-0514 Cylinder Liner Flange 3
24 T507-305.00 Locking nut M39×3 3
25 AH130101-052300 Spacer Unit 4
26 520203080200400002 Imperial Internal connector NPT 1 1/2" 1
27 AH100101-0526 Suction Flange（Ⅱ） 1
28 530301013450070015 O-Ring 345×7.00FPM 3
29 AH100101-0525 Suction Flange（I） 1
30 420201011127090060 Bolts M27×90-8.8-Zn.D 36
31 AH000005-0800 Suction Dampener 1
32 420402016270400000 Nuts M27-8-Zn.D 36
33 AH100101-0527 Washer 39 30
34 420201011122050060 Bolts M22×50-8.8-Zn.D 18
35 AH160201-012000B3 Spray Pipe Assembly 1
36 AH100101-0515B1 Piston Seals 3
37 AH160201-0121 90°Elbow NPT3/8 3
39 170506010100243000 Anaerobic adhesive - Loctite 243 1
Imperial low-pressure Stainless Ball
40 441305011104164038 3
Valve Q11SF-16P NPT1 1/2"
41 AH160201-0107B1 Wear Plateφ180 3
42 AH160201-0116B7 Cylinder Liner Seals (φ220) 3
43 AH130101-0516 Piston Rod 6
44 AH160201-012300 Bonnet Assembly 3

67
10.2.2.1 Piston（AH160201-011100）
No. Drawing No. Description Qty.
1 AH010004-1000 Piston φ190（HNBR） 1
2 AH010004-0900 Piston φ180（HNBR） 1
3 AH010004-0800 Piston φ170（HNBR） 1
4 AH010004-0700 Piston φ160（HNBR） 1
5 AH010004-0600 Piston φ150（HNBR） 1
6 AH010004-0500 Piston φ140（HNBR） 1
7 AH010004-0400 Piston φ130（HNBR） 1
8 AH010004-0300 Piston φ120（HNBR） 1

10.2.2.2 Cylinder Liner（AH160201-011800）

No. Drawing No. Description Qty.
1 AH000003-051100 Bi-metal liner φ120 1
2 AH000003-051200 Bi-metal liner φ130 1
3 AH000003-051300 Bi-metal liner φ140 1
4 AH000003-051400 Bi-metal liner φ150 1
5 AH000003-051500 Bi-metal liner φ160 1
6 AH000003-051600 Bi-metal liner φ170 1
7 AH000003-051700 Bi-metal liner φ180 1
8 AH000003-0508 Cylinder Liner φ190（general） 1
Note: The cylinder liner in the table above is used in conjunction with the wear-resistant disc
diameter 190 (drawing number: AH160201-0107B2), and the corresponding cylinder liner
sealing ring in the table below is used.

Cylinder seals used at all levels

No. Description
1,2 AH160201-0116B4
3,4 AH160201-0116B5
7,8 AH160201-0116B6
5,6 AH160201-0116B7
The cylinder liner with a diameter of φ 150~ φ 180 can be used with the cylinder liner of
F-1600 pump. At this time, a special wear-resistant disc with a diameter of φ180 (drawing
number: AH160201-0107B1) and a cylinder liner sealing ring (drawing number:
AH130101-0512) should be used simultaneously. The cylinder liner with a diameter of φ
150~φ180 for F-1600 pump has the following drawing numbers, respectively.
No. Drawing No. Description Qty.
1 AH000003-031400 Bi-metal liner φ150 1
2 AH000003-031500 Bi-metal liner φ160 1
3 AH000003-031600 Bi-metal liner φ170 1
4 AH000003-030700 Cylinder Liner φ180 1
Regardless of the use of any of the above wear-resistant discs, the sealing ring of the
wear-resistant disc is installed according to AH160201-0115.

68
10.2.2.3 Valve Assembly（API 7）（AH160201-011900B1）

No. Drawing No. Description Qty.

1 AH160201-011902B1 Valve Seat 1
2 AH160201-01190101B1 Valve Body 1
3 AH000002-030102 Valve Nut 1
4 AH000002-010203 Circlip 1
5 AH000002-010204 Gland 1
6 437101010500000000 Steel ball φ5 46
7 AH220201-052205B1 Valve Rubber 1
8 AH000002-030104 Valve Guide Frame 1
Anaerobic adhesive -
9 170506010100243000 1
Loctite 243

69
10.2.2.4 高压阀总成（API 7H） (AH000002-0900B1)

序号 图号 名称 数量
1 AH000002-0901B1 Valve Body 1
2 AH000002-0902B1 Valve Seat 1
3 AH000002-0903B1 Valve Rubber 1
4 AH000002-010202 Valve Nut 1
5 AH000002-010203 Circlip 1
6 AH000002-010204 Gland 1
7 AH000002-050205 Valve Guide Frame 1
8 437101010500000000 Steel ball φ5 46
Anaerobic adhesive - Loctite
9 170506010100243000 1
243

70
10.2.2.5 Discharge Hydraulic Cylinder Assembly（AH160201-010400）

No. Drawing No. Description Qty.

1 AH160201-010401B1 Discharge Hydraulic Cylinder 1
2 T503-3005 Stud AM39×2-M39×3×130 10
3 T507-2011 Nuts M39×3 10
4 T503-3008 Stud AM27×2-M27×3×195 12
5 AH130101-050102 Nuts M27 12
6 T507-2007 Nuts M42×3 4
7 T503-3015 Stud AM42×2-M42×3×170 4
8 T503-3024 Stud M45×2-M45×3×610 6
9 T507-2008 Nuts M45×3 6
10 170506010100243000 Anaerobic adhesive - Loctite 243 1
External Gear Lock washers NL45
11 420505032450180000 6
EN1.7182 flZn

71
10.2.2.6 Suction Pipeline（AH160201-010500B1）

No. Drawing No. Description Qty.

1 AH100101-052302 Flange（Ⅱ） 3
2 AH100101-052303 Flange（Ⅲ） 3
3 AH160201-01050001B1 Short Connector L=139 3
4 AH160201-01050002B1 Steel Pipe L=2033.4 1
5 AH160201-01050003B1 Rib Plate 4
6 AH130101-052201 Sub-plate 2
7 AH160201-01050004B1 Short Connector L=351 1
8 AH220201-052101B1 Blind Flange 3
9 AH220201-052102B1 Flange 3
10 AH160201-01050005B1 Short Connector 3
11 530301011850070015 O-Ring 185×7.00FPM 3
12 420201011116065060 Bolts M16×65-8.8-Zn.D 24
13 420402016160400000 Nuts M16-8-Zn.D 24

72
10.2.2.7 Suction Dampener (AH000005-0800)

No. Drawing No. Description Qty.

1 AH100101-0526 Suction Flange（Ⅱ） 1
90°Welding Elbow 90E(S)
2 520402020013000401 1
300Ⅱ-Sch40
3 AH000005-080001 Steel Pipe L=1013 1
4 AH000005-080002 Steel Pipe L=85 1
5 520405010013000101 Welding Tube Cap C 300Ⅱ-Sch40 1
6 AH000005-0602 Connector 3
7 AH000005-0603 Pipe Blocking M24×2 3
8 530301010250035515 O-ring 25×3.55FPM 3
9 530301013450070015 O-ring 345×7.00FPM 1

73
10.2.3 5" Auxiliary Pipeline（52MPa）（AH160201-0200B1）

No. Drawing No. Description Qty.

1 AH160201-0201B1 5-Way 1
2 AH160201-020200B1 Filter Drum Assembly 1
3 AH160201-0203B1 Flange 1
4 AH160201-020400B1 Connection Flange Assembly 1
5 AH160201-0205B1 5 1/8×69MPa Welded Neck Flange 1
6 AH160201-0122B1 Bonnet Seals 1
7 T503-4014 Stud AM30×2-M30×3×120 36
8 T507-2001 Nuts M30×3 36
9 170506010100243000 Anaerobic adhesive - Loctite 243 80ml
10 T503-4013 Stud AM39×2-M39×3×150 12
11 T507-2011 Nuts M39×3 12
12 T508-6001 Rim BX-169 2
13 AH160201-0206B1 Filter warning sign 2
14 420101063104000800 Stainless cross slot screws M4×8 8

10.2.3.1 Filter Drum Assembly（AH160201-020200B1）

No. Drawing No. Description Qty.

1 AH160201-020201B1 Gland 1
2 AH160201-020202B1 Filter Drum 1

74
 3 170506010100243000 Anaerobic adhesive - Loctite 243 1
10.2.3.2 Connecting Flange Assembly（AH160201-020400B1）

No. Drawing No. Description Qty.

1 AH160201-020401B1 90°Elbow 1
2 AH160201-020402B1 Non-standard Welding Neck Flange 2 1/16 1
3 AH160201-020403B1 5 1/8×69MPa Welding Neck Flange 1
4 T508-6002 Rim BX152 1
5 T503-1008 Stud M20×140 8
6 T507-2013 Nuts M20 16

10.2.4 Crankshaft Assembly（AH160101-0100）

75
 No. Drawing No. Description Qty.
1 AH130101-020100B2 Main Bearing End-cap 2
2 Main Bearing Sleeve
1
AH160101-0101 (Right)Connecting Rod
3 AH130101-0203 Seals Ring 2
4 AH130101-0204 Inner Gasket 2
5 AH160101-010200B1 Outer Gasket 3
6 AH160101-0103 Connecting Rod 3
7 AH130101-0207 Locating Ring(I) 1
8 AH130101-020800 Hollow Crankshaft 1
9 AH130101-0209 Locating Ring(Ⅱ) 1
10 AH130101-0211 Spacer Ring 2
11 AH160101-0105 Circle Main Bearing Sleeve (Left) 1
12 AH160101-0106 Retainer 2
13 AH130101-0214 Baffle 2
14 AH130101-0215 Bolts of Main Bearing 4
15 AH130101-021600 Spacers Unit 1
16 T502-6006K Hexagon Socket Screws M16×120 2
17 T507-2011 Nuts M39×3 12
18 T502-7003K Bolts M16×40 72
19 420201011116045060 Bolts M16×45-8.8-Zn.D 28
20 430129150464777019 5/8-11UNC×4 3/4 3
21 430103002316000012 Eccentric Wheel Bearings 2
22 420501036160200000 Small Washer 16-140HV-Zn.D 28
23 AH160101-010001 Lock-wire φ1.5 5
24 AH160101-010002 Lock-wire φ3 1
25 170506010100243000 Anaerobic Adhesive - Loctite 243 1
26 T502-6004K Hexagon Socket Screws M16×100 2
27 T502-3008 Bolts M39×3×180 12
28 170506040176759000 Loctite 76759 Anti-bite Agent 1
29 AH160101-010900 Bull Gear 1
30 External Gear Lock Washers NL39
420505032390180000 24
EN1.7182 flZn

10.2.4.1 Main Bearing End-cap (AH130101-020100B2)

76
 No. Drawing No. Description Qty.
1 AH050101-020101B1 Handle 2
2 AH130101-02010001B
Flange 1
2
3 AH130101-02010002B
End-cover 1
2
4 AH130101-02010003B
Process clamp L=1000 4
3

10.2.5 Lubrication Assembly of Power End（AH130101-0600B3）

77
No. Drawing No. Description Qty.
1 AH130101-0601B3 Brassφ8×550 2
2 AH130101-0602B3 Brassφ8×1124 2
3 AH130101-0603B3 Brassφ12×1099 1
4 AH130101-0604B3 Brassφ8×358 2
5 AH130101-0605B3 Brassφ8×552 2
6 AH130101-0606B3 Brassφ8×600 2
7 AH130101-0607B3 Brassφ12×600 1
8 AH130101-060800B3 Three Pipes Clamp Assembly (I) 1
9 AH130101-060900B3 Double Pipes Clamp Assembly (I) 1
10 AH130101-061000B3 Double Pipes Clamp Assembly φ8 1
11 AH130101-061100B3 Single Pipe Clamp Assembly φ8 6
12 AH130101-061200B3 Five Pipes Clamp Assembly 1
13 AH130101-061300B3 Four Pipes Clamp Assembly 1
14 AH100101-0607 Connector Seat (Ⅰ) 1
15 AH130101-0614B3 Brassφ8×681 1
16 AH130101-0615B3 Brassφ8×1153 1
17 AH130101-0616B3 Brassφ8×976 1
18 AH130101-0617B3 Brassφ8×366 1
19 AH130101-0618B3 Brassφ8×439 1
20 AH130101-0619B3 Brassφ8×159 1
21 AH130101-0620B3 Brassφ8×605 1
22 AH130101-0621B3 Brassφ8×844 1
23 AH130101-0622B3 Brassφ8×210 1
24 AH130101-0623B3 Brassφ8×1255 1
25 AH130101-0624B3 Connector Seat（II) 1
26 AH130101-0625B3 Brassφ16×453 1
27 AH130101-0626B3 Brassφ8×298 1
28 AH130101-060001B3 Brassφ8x260 2
29 AH130101-060002B3 Brassφ12x900 1
30 AH130101-060003B3 Brassφ12×670 2
31 AH130101-060004B3 Brassφ8×602 2
32 AH130101-060005B3 Brassφ8×305 2
33 AH130101-060006B3 Brassφ12×152 2

78
34 AH130101-060007B3 Brassφ8×942 1
35 AH130101-060008B3 Brassφ8×966 2
36 AH130101-060009B3 Brassφ8×412 1
37 AH130101-060010B3 Brassφ8×436 2
38 AH130101-060011B3 Brassφ12×412 1
39 AH130101-060012B3 Brassφ22×260 1
40 520901030333000010 Straight Pipe Fittings L12/NPT3/8 6
41 520901030332000010 Straight Pipe Fittings L8/NPT1/4 11
42 520901030333100010 Straight Pipe Fittings L16/NPT1/2 1
43 520901031533200010 Right Angle Fittings L8 6
44 520901031531500010 Right Angle Fittings L12 1
45 520901031332000010 Right Angle Fittings L8/NPT1/4 15
46 520902020931500010 Straight Pipe Fittings L12 2
47 520902020933200010 Straight Pipe Fittings L8 8
48 AH100101-061400 Safety Valve Assembly 1
49 512601010031000000 Gear Pump 2S 1
50 AH100101-060400 Spacer Unit 1
51 AH130101-060200 Seat 1
52 AH050101-060200B1 Hydraulic Display Device 1
53 420201011106020060 Bolts M6×20-8.8-Zn.D 4
54 420503016061600000 Standard Spring Washer 8-Zn.D 4
55 AH080101-0603 Tee 2
56 AH130101-0601 Oil Nozzle 2
57 AH100101-0613 Positioning Block 2
58 AH100101-061200 Oil Pump Gear Assembly 1
59 T516-2001 Square Key 3/16×3/16×1 1
60 420101121108004006 Hexagon Socket Screws M8×40-8.8-Zn.D 8
61 420503016081600000 Standard Spring Washer 8-Zn.D 8
62 520901031333100010 Right Angle Fittings L16/NPT1/2 3
63 520901030332100010 Straight pipe fittings L22/NPT3/4 2
64 AH100101-060100B1 Oil Filter Assembly 1
65 T007-012.00 Adsorption Magnet 1
66 T511-3006 90°Elbow NPT1/2×NPT3/4 1
67 520902540320120100 Hollow BoltsA12 2
68 AH100101-0608 45°Pipe Fittings 2
69 520902551280120100 Adhesive pad A12 2
70 T506-1002 Plug NPT1/4 5
71 T511-3002 90°Elbow NPT1/4-NPT3/8 3
72 170506010100609000 Loctite 609 Lock Agent 1
73 T506-1005 Plug NPT3/4 2
74 AH220201-0602 90°Elbow NPT1/4-NPT1/4 2

79
10.2.5.1 Safety Valve Assembly（AH100101-061400）

No. Drawing No. Description Qty.

51270402000003201
1 1
4 Safety Valve AF-E20/0.5
Internal Fitting of Straight Pipe
2 1
T001-0328 NPT1/2-R3/4
52020104020015000
3 1
3 Imperial Conical Fitting NPT 1/2"

10.2.5.2 Hydraulic Display Device（AH050101-060200B1）

No. Drawing No. Description Qty.

1 AH050101-06020100B1 Pressure Gauge Cover 1
Dual Scale Pressure Gauge YTN60
2 380202051160006050 1
1.6MPa/230PSI NPT1/4
3 AH050101-060202B1 Tee NPT 1/4 1
4 AH050101-060203B1 Washer 20 1
5 AH050101-060204B1 Plug 1
6 AH050101-060205B1 Inside & outside Fitting 1
7 140507011301008040 Assembly Hose 13Ⅰ-D-3225 1
8 AH050101-06020600B1 Clamp Assembly 3
9 AH050101-060207B1 90°Pipe Fitting 1
80
 10 420201011110020060 Bolts M10×20-8.8-Zn.D 4
11 420503016101600000 Standard Spring Washer 10-Zn.D 4
12 AH050101-060208B1 PadⅠ 1
13 AH050101-060209B1 PadⅡ 1
14 T001-0804 Straight Fitting NPT1/4-M22×1.5 2
15 AH050101-060210B1 Support 1

10.2.5.3 Oil Pump Gear Assembly (AH100101-061200)

No. Drawing No. Description Qty.

1 AH100101-061201 Oil Pump Gear 1
2 AH100101-061202 Bearing Sleeve 1
3 420201061110035060 Bolts M10×35-8.8-Zn.D 3
4 420503016101600000 Standard Spring Washer 10-Zn.D 3

81
10.2.6 Pinion Shaft Assembly（AH160101-0200）

No. Drawing No. Description Qty.

1 AH130101-0301 Key 2〃×2〃×11 3/8〃 1
2 AH130101-0303 Wear Sleeve 2
3 AH130101-0304 End cap 2
4 AH130101-0305 Gasket 2
5 AH130101-0306 Gasket 2
6 AH130101-030700 Bearing Sleeve Assembly 2
7 AH130101-0308 Retainer 2
8 AH130101-0309 Gasket 2
9 AH130101-031000 Oil Collector 2
10 420201011112040060 Bolts M12×40-8.8-Zn.D 24
11 420201011122050060 Bolts M22×50-8.8-Zn.D 16
12 AH130101-0311 Oil Seal 9.125″×10.375″×0.625″ 2
13 430110010304400017 Input Shaft Bearing 2
14 420503016221600000 Standard Spring Washer 22-Zn.D 16
15 420503016121600000 Standard Spring Washer 12-Zn.D 24
16 AH130101-0313 Turn-pump Flange 1
17 420201011116045060 Bolts M16×45-8.8-Zn.D 3
18 420503016161600000 Standard Spring Washer 16-Zn.D 3
19 AH160101-020100B1 Pinion Shaft 1

82
10.2.7 Hoisting (AH130101-1000)

No. Drawing No. Description Qty.

1 AH130101-1001 Pin 1
2 AH130101-1002 Pad I 14
3 AH130101-1003 Lateral Plate 2
4 AH130101-1004 Lifting board 1
5 AH130101-1005 Small Shaft 4
6 AH130101-1006 Pad II 8
7 AH130101-1007 Sleeve 4
8 AH130101-1008 Bearing Gland I 4
9 AH130101-1009 Paper Pad 4
10 AH130101-1010 Wheel 4
11 AH130101-1011 Bearing Gland II 4
12 AH130101-1012 Paper Pad 4
13 AH130101-1013 Angle Steel 4
14 AH130101-1014 Cover 2
15 420101030705000806 Slotted Countersunk Screw M5×8-4.8-Zn.D 24
16 430107000630500000 Deep Groove Ball Bearings 6305 4
17 420201011106016060 Bolts M6×16-8.8-Zn.D 24
18 420503016061600000 Standard Spring Washer 6-Zn.D 24
19 AH130101-100001 Felt Seals φ40×24×5.5 4
20 420503016161600000 Standard Spring Washer 16-Zn.D 4
21 420402016160400000 Nuts M16-8-Zn.D 4
22 420402016240400000 Nuts M24-8-Zn.D 1

83
10.2.8 Spray Pump Assembly (AH160201-1200B1)

No. Drawing No. Description Qty.

1 AH160201-120100B1 Seat 1
2 AH160201-120200B1 Connection Board 1
3 AH160201-120300B1 Water Tank 1
4 AH160201-120500B1 Tank Cover Assembly 1
5 AH220201-0802B2 Discharge Flange 1
6 AH220201-080300B2 Suction Flange 1
7 AH220201-0804B2 Gasket 2
8 AH220201-0805B1 Fitting ZG2 1/2 1
9 AH160201-120001B1 Connection Pipe R2 1/2×NPT2 1/2，L=95 1
10 260101011723000000 Electric Spray Pump 40SB180J-3KW 1
11 420201011116060060 Bolts M16×60-8.8-Zn.D 4
12 420402016160400000 Nuts M16-8-Zn.D 4
13 420503016161600000 Standard Spring Washer 16-Zn.D 4
14 520207050400650002 Imperial Elbow Rc2 1/2" 1
15 AH160201-120002B1 Hose L=360 1
16 429901020070570000 German Hose Clamp d70 2
17 T001-0315 Fitting NPT1 1/2 1
18 British Low-pressure Stainless Ball Valve
441305011104164038 1
Q11SF-16P NPT1 1/2"
19 520201070020020000 Cone Jjoint 40-M56X2（NPT1 1/2） 2
20 Cone Seal Cotton Tube Assembly
1
140507163800020501 38-2050
21 420201061112055060 Bolts M12×55-8.8-Zn.D 12
22 420402016120400000 Nuts M12-8-Zn.D 12
84
 23 420503016121600000 Standard Spring Washer 12-Zn.D 12

10.2.9 Crosshead Assembly (AH130101-0400)

No. Drawing No. Description Qty.

1 AH130101-0401 Crosshead 1
2 AH130101-0402 Upper Guide 1
3 AH130101-0404 Packing Box 1
4 AH130101-0405 Oil Seal Ring 1
5 AH130101-0406 Skeleton D-lips Oil Seal 5″×6.25″×0.625″ 2
6 AH130101-0407 Lock Spring 1
7 AH130101-0408 Fender 1
8 AH130101-0409 Pony Rod 1
9 AH130101-0410 Crosshead Pin 1
10 AH130101-0411 Gasket 1
11 AH130101-0412 Lower Guide 1
12 AH130101-0413 Crosshead Pin Baffle 1
13 AH130101-0415 Gasket 1
14 AH130101-040001 Anti-loose Wire 1
15 AH100101-0405 Pipe Fitting 3/8" 2
16 AH100101-0410 Fastening Plate 8
85
 17 AH100101-041700 Spacer Unit 8
18 T502-6005K Hexagon Socket Screws M24×65 8
19 530301011250070001 O-ring 125×7.00NBR 1
20 420101121120006506 Hexagon Socket Screws M20×65-8.8-Zn.D 8
21 530301011600070001 O-Ring 160×7.00NBR 1
22 430129140061206023 Crosshead Bearing 1
23 420201041124060060 Bolts M24×60-8.8-Zn.D 2
24 420201041124070060 Bolts M24×70-8.8-Zn.D 6
25 420201011110025060 Bolts M10×25-8.8-Zn.D 4
26 420503016101600000 Standard Spring Washer 10-Zn.D 4
27 420501066100100000 Flat Washer C 10-100HV-Zn.D 4
28 170506010100243000 Anaerobic adhesive - Loctite 243 1
10.2.10 JAF-3×52 Flange Type Shear Pin Safety Valve (AH000006-1000)

No. Drawing No. Description Qty.

1 AH000006-1001 Nameplate 1
2 AH000006-1002 Inlet Flange 1
3 AH000006-0801B1 Piston Rod 1
4 AH000006-0802 Valve Body 1
5 AH000006-0304B1 Cushion 1
6 AH000006-0903 Outlet Flange 1
7 AH000006-070300 Transition Sleeve Assembly 1
8 AH000006-0305 Lock Spring 1
9 AH000006-0306 Safety Cover 1
10 AH000006-0307 Shear Pin Plate 1
11 AH000006-0308 Shear Pin 2
12 AH000006-0310 Pin 1
13 AH000006-0804 SignageⅠ 1
14 AH000006-0805 SignageⅡ 1
15 AH000006-0707 Retainer 1
16 AH000006-010300 Piston Assembly 1
17 AH000006-0708 Retainer 1
18 530301010690053001 O-ring 69×5.30NBR 1
19 420701051605006010 Elastic Cylindrical Pin 5×60-Zn.D 1
86
 20 420603021016140000 Steel Retainer of Shaft16 2
21 420402016100400000 Nuts M10-8-Zn.D 1
22 420201011110110060 Bolts M10×110-8.8-Zn.D 1
23 420101023404001600 Stainless Slotted Screws M4×16 2
24 420101023803000800 Stainless Slotted Screws M3×8 8
25 530301010750053001 O-RING 75×5.30NBR 2
26 420402010043800000 Stainless Steel Nuts M4 2
27 420703020802502060 Cotter Pin 2.5×20-Zn.D 1
28 420703024103202500 Stainless Cotter Pin 3.2×25 1
Hexagon Socket Screws
29 420101121120006506 16
M20×65-8.8-Zn.D
30 420402136120200000 Slotted Thin Nuts M12-5-Zn.D 1
31 420501016120300000 Flat Washer A 12-200HV-Zn.D 1

Shear Pin Safety Valve (AH000006-0300)

No. Drawing No. Description Qty.

1 AH000006-0301 2 1/16＂×69 MPa Flange 1
2 AH000006-0302 Valve Body 1
3 AH000006-0303 Piston Rod 1
4 AH000006-0304B1 Cushion 1
5 AH000006-0305 Lock Spring 1
6 AH000006-0306 Safety Cover 1
7 AH000006-0307 Shear Pin Plate 1
8 AH000006-0308 Shear Pin 2
9 AH000006-0309B1 Nameplate 1
10 AH000006-0310 Pin 1
11 AH000006-0311 Signage Ⅰ 1
12 AH000006-0312 Signage Ⅱ 1
13 AH000006-0102 Retainer 1
87
 14 AH000006-010300 Piston Assembly 1
15 420701051605006010 Elastic Cylindrical Pin 5×60-Zn.D 1
16 420603021016140000 Steel Wire of Shaft 16 2
17 420402076100400000 Slotted Nuts M10-8-Zn.D 1
18 420201011110110060 Bolts M10×110-8.8-Zn.D 1
19 420101020704001606 Slotted Screws M4×16-4.8-Zn.D 2
20 420101023403000800 Stainless Slotted Screws M3×8 8
21 420703020504002500 Cotter Pin 4×25 1
22 420402016040200000 Nuts M4-5-Zn.D 2
23 420703024002502000 Stainless Cotter Pin 2.5×20 1

10.2.11 WY-75-52 Pulsation Dampener（Imperial）(AK755201-00)

No. Drawing No. Description Qty.

1 AK755201-0100 Shell Assembly 1
2 AK755201-02 Cover 1
3 AK755201-0300 Pressure Gauge Cover Assembly 1
4 AK755201-0400 Bladder Assembly 1
5 T508-6003 Seal Rim BX155 1
6 T001-4201 Tee NPT 1/4＂ 1
7 AK455201-04 Fitting 1
8 512604900000030801 Exhaust Valve NPT1/4 1
Dual Scale Pressure Gauge Y-60
9 380202052250006020 1
0-25MPa/3630PSI NPT1/4"
10 WG07132101 Right Angle Stop Valve NPT 1/2＂-70 MPa 1
11 AK755201-0400B1 High Temperature Bladder Assembly 1

88
10.2.11.1 Shell Assembly (AK755201-0100)

No. Drawing No. Description Qty.

1 AK755201-0101 Shell 1
2 AK755201-0102 Transition Flange 1
3 AK755201-0103 Stud AM30×2-M30×3×110 8
4 AK755201-0104 Hexagon Socket Screws M33×3×75 8
5 AH220201-0520 Hydraulic Cylinder Seals 1
6 T503-4015 Stud AM48×2-M48×3×175 16
7 T507-2017 Nuts M48×3 16
8 T507-2001 Nuts M30×3 8
9 170506010100243000 Anaerobic adhesive - Loctite 243 1
10 530301011280070015 O-ring 128×7.00FPM 1

Inflatable instructions
1. Remove the dampener pressure gauge cover and rotate the exhaust valve cover about
1/4 to 1/2 of the revolution to vent the air pressure stored in the gauge area and remove the
vent valve.
2. Connect hose to nitrogen cylinder valve and dampener inflation valve.
3. Open the dampener inflation valve.
4. Slowly open the nitrogen cylinder valve and use this valve to regulate the air flow into
the dampener.
5. When the dampener pressure indicates the desired pressure, close the valve of empty
cylinder.
6. Close the dampener valve.
7. Remove the hose, cover the pressure gauge cover, and install the vent valve again.
8. For best results, the dampener pre-charge pressure must not exceed 2/3 of the pump
discharge pressure, but the maximum charge pressure is 8.6 MPa (1250 psi).

Warning: Use only compressed or compressed air - Do not use

oxygen.

89
10.2.12 Spare Parts of F-1600HL Mud Pump (AH160201-0800)

No. Drawing No. Description Qty.

1 AH130101-0311 Oil Seals 9.125″×10.375″×0.625″ 2
2 AH130101-0406 Oil Seals FDB127×158.75×15.9F 6
3 530301011600070001 O-ring 160×7.00NBR 3
4 530301011250070001 O-ring 125×7.00NBR 3
5 AH130101-0415 Gasket 3
6 530301010412035515 Oil Ring 41.2X3.55 1
7 T508-6002 Rim BX152 2
8 T508-6001 Rim BX169 8
9 T508-6003 Seals Rim BX155 2
10 AK755201-0400B1 High Temperature Bladder Assembly 1
11 AH100101-09B1 Sealing ring 2
12 AH130101-0405 Oil seal ring 3
13 AH160201-0116B4 Hydraulic Linder Seals（φ170） 3
14 AH160201-0116B5 Hydraulic Linder Seals（φ185） 3
15 AH160201-0116B6 Hydraulic Linder Seals（φ220） 3
16 530301011850070015 O-Ring 185×7.00FPM 6
17 AH160201-0115 Wear Plate Seals 3
18 AH160201-0114 Exhaust Pipe Seals 3
19 AH160201-0122B1 Bonnet Seals 7
20 530301012000070015 O-ring 200×7.00FPM 3
21 530301013450070015 O-ring 345×7.00FPM 3
22 AH160201-011900B1 Valve assembly API 7 6
23 AH160201-0113 Hydraulic Cylinder Seals 3
24 AH010004-0300 Piston φ120 HNBR 3
25 AH100101-210604 Retainer φ200×φ185×2.5 1
26 AH100101-210605 O-ring φ200×8.6 1
27 AH100101-210606 Retainer φ80×φ70×2 1
28 AH100101-210607 O-ring φ80×5.7 1
29 530301010250035515 O-ring 25×3.55FPM 3
30 AH220201-0520 Hydraulic seals 1
31 530301011280070015 O-ring 128×7.00FPM 1
32 AH160201-0116B7 Hydraulic Linder Seals（φ200） 3
33 T508-6006 Seals Rim BX154 2
34 AH160201-012401 O-ring φ30 3
35 T508-6006 Rim BX154 2

10.2.13 Tools of F-1600HL Mud Pump(AH160201-0900)

No. Drawing No. Description Qty.

1 AH160201-090100 Hydraulic Valve Puller 1
2 AH160201-0909 Hammer Wrench S65(M42) 1
3 AH160201-0910 Hammer Wrench S70(M45) 1
4 AH130101-160100 Cylinder Liner Hoisting Tools 1
5 AH100101-2108 Sleeve 2 3/8 1
6 AH100101-2109 Sleeve 2" 1
7 AH130101-1602 Sleeve 3 5/8 1
8 AH130101-1603 Sleeve 1 1/2 1
9 AH130101-1604 Transition Joints 1
90
 10 AH130101-1605 19 5/8 Extension Bar 1
11 AH100101-2110 8" Extension Bar 1
12 AH100101-2111 Joint 1" 1
13 AH100101-2112 24" Extension Bar 1
14 AH130101-1611 Bolts M24×220 4
15 AH130101-161000 Long Sleeve 1
16 AH100101-210700 Dampener Inflatable Hose Assembly 1
Manual Charge-oil Pump P77 with
17 512605040000500002 Pressure Gauge and 6m High Pressure 1
Hose
18 390101010100500000 Chain Hoist HS1/2 1
19 400101091700000000 Allen Wrench17 1
20 AH100101-210100 Cylinder Head Stick 1
21 AH100101-2115 Adapter 1
22 AH130101-161400 Piston Nuts Dismantling Rack 1
23 420102012516000006 Rings Screws M16-Zn.D 2
24 AH300201-280400 T-type Wrench 1
25 AH300201-2805 Sleeve S19 1
26 AH130101-1607 Packing Guide Sleeve 1
10.2.14 Hydraulic Valve Puller（AH160201-090100）

91
 No. Drawing No. Description Qty.
1 AH160201-090101 Screw 1
2 AH160201-090102 Support Seat 1
3 AH130101-16060200 Hook Assembly 1
4 AH100101-210608 Cylinder Seat 1
5 AH100101-210602 Cylinder Head 1
6 AH100101-210604 Retainerφ200×φ185×2.5 1
7 AH100101-210605 O-ringφ200×8.6 1
8 AH100101-210603 Locating ScrewM10 6
9 AH100101-210606 Retainer φ80×φ70×2 1
10 AH100101-210607 O-ringφ80×5.7 1
11 AH100101-210601 Cambox 1
12 AH100101-210612 Right Angle Connector 1
13 T514-1002 Washer 1
14 AH130101-210614 Plug M16×1.5 1
15 AH100101-210613 Handle 2
16 AH100101-210615 Nuts M48×3 1

10.2.15 Dampener Inflatable Hose Assembly AH100101-210700

No. Drawing No. Description Qty.

1 AH100101-210701 Nut G5/8 1
2 AH100101-210702 Sealing joint 1
3 AH100101-210703 Joint 1
4 AH100101-210704 Seal gasket 1
5 AH100101-210705 Screw 1
6 140507020601050030 Hose assembly 6Ⅰ-C 1

92