Operating Instructions

For LGF-1000 Drilling Pump

Sichuan Gaosheng Machinery Manufacturing Co., Ltd.

Tel: 028-85730676 , 028-85730698 Add.: Jiaolong Industrial Zone, Shuangliu County, Chengdu, China

CONTENTS
1. Overview 2. Technical Specifications 3. Flow Rate vs. Pressure 4. Features of Main Components 5. Assembly and Disassembly of Main Components 6. Assembly, Startup and Running Monitoring of Drilling Pump 7. Maintenance 8. Troubleshooting 9. Notes for Storage 10. Special Lubrication Oil and Grease 11. List of Supplied Special Tools 12. Recommended Order List 13. List of LGF-1000 Drilling Pump Drawings 14. List of Spare Parts

1. Overview
LGF-1000 drilling pump is a kind of horizontal triplex single-acting piston pump, made up of power end and fluid end, designed with advanced structure, small size, reliable operation mechanism, exchangeable components, and easy maintenance. The consumables, bearings, sealing parts and technical parameters of this pump are the same as those of F-1000 pump. The power end includes framework, pinion shaft assembly, crank shaft assembly, crosshead assembly and pony rod, etc. The fluid end includes module, valve assembly, liner, piston assembly, suction manifold, etc. In order to avoid gas lock and reduce the pressure pulsation at the discharge outlet, a suction pulsation dampener and a discharge pulsation dampener are installed respectively at the suction pipe and the pump outlet. And a shear-pin safety valve is installed at the other end of the pump outlet to ensure the pump pressure not to exceed the rated working pressure. Splash lubrication and forced lubrication are combined for the gears, bearings and crosshead at the power end to ensure sufficient lubrication, while the water supplied by spray pump is used to lubricate, clean and cool the liner and piston at the fluid end. A special set of handling (assembly and disassembly) tools are provided for routine maintenance of the drilling pump. When LGF-1000 drilling pump remains in good condition it will be an excellent partner of every drilling worker and bring you great benefits.

2. Technical Specifications
No. 1 Description Type Parameters Horizontal, pump 2 3 4 5 6 7 8 9 Rated input power (HP) Rated strokes Stroke length Gear type Gear ratio Suction connection size Discharge connection size Pinion shaft diameter 735KW(1000HP) 140 254 mm (10in.) Herringbone tooth 4.207:1(122:29) 12 flange 5-1/8flange 5000#API and 196.85/7-3/4 336.55/13-1/4 triplex single-acting piston

extension (mm/in.) 10 11 12 Key connection size (mm/in.) Module Dimensions mm in. 13 14 Base width (mm/in.) Pump weight (kg/lb) 50.850.8 / 22 API 6#142.875/5-5/8 426931671818 168124-5/871-1/16 1790/70 1/2 18790/41420

3. Flow Rate vs. Pressure

Liner ID (in) Rated WP (MPa Strokes per Power HP
6 3/4 16.4 6 1/2 17.6 6 1/4 19.1 6 20.7 5 1/2 24.6 5 29.8 4 1/2 34.5

Flow Rate

(L/s)

Minute
spm 140 130 120 110 100 1

KW

HP

735 683 630 578 525 5.25

1000 929 857 786 714 7.14

41 38.07 35.14 32.21 29.28 0.293

38 35.28 32.57 29.85 27.14 0.271

35.2 32.68 27.86 27.66 25.14 0.251

32.4 30.1 27.77 25.46 23.14 0.231

27.2 25.26 23.3 21.37 19.43 0.194

22.5 20.89 19.28 17.68 16.07 0.161

18.2 16.9 15.6 14.3 13 0.130

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

4. Features of Main Components

LGF-1000 pump consists of 2 parts, power end and fluid end. The power end is used to provide adequate power to the fluid end, and the fluid end is used to convert the mechanic energy to the internal energy of the fluid to convey drilling mud. The combination connection of framework, base support, cylinder, suction pipe and discharge pipe forms the whole set, characteristic of small in size, high in strength, and compact in structure. Please refer to Fig. 1.

Crankshaft Assembly Framework Assembly

Pinion Shaft Assembly

Crosshead Assemblies

Fluid End Assembly

Discharge Pipe

Suction Pipe

Fig.1

Structural Schematics of LGF-1000 Drilling Pump

1) Power End The power end includes framework, pinion shaft assembly, crank shaft assembly, and crosshead assembly. a. Framework The framework is the base of the LGF-1000 pump, all pump components are installed on the framework. It is welded in the form with steel plates. And stresses have been treated already, with high rigidity and high strength. All necessary oil pools and oil passages are designed in the framework, used for lubrication and cooling. b. Pinion Shaft Assembly The pinion shaft is made of forged alloy, with herringbone teeth and medium-hard tooth surface. It turns smoothly and has a high efficiency and a long service life. Roller bearings are placed at the journal area without retaining edge at the inner race, so as to facilitate the repair check. Both ends of the shaft extend out, belt wheel or chain wheel can be mounted at either end, with the other end installed with pulley sheave which drives spray pump or charge pump. c. Crank Shaft Assembly The bull gear, connecting rod and bearings can be installed respectively on the crankshaft. The bull gear will engage with the gears on the pinion shaft. A tight fit exists between
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the inside of the bull gear and the crank shaft, with 12 bolts to connect and locknuts to tighten. d. Crosshead Assembly The coaxiality between the crosshead and the guide can be adjusted by inserting spacers at the lower guide. The crosshead and the connecting rod are connected by rabbet locating bolts, to ensure the two aligned axially. The bolts are tightened according to required torque value, and locking wires used. A crosshead pin is used at the middle of the crosshead to connect with the small end of the connecting end. For easy assembly and disassembly, a tapered fit is used between the crosshead and the pin, with a clamp plate pressed tightly the crosshead at the big end, and bolts tightened with the torque required, and locked by wires. 2) Fluid End The fluid end includes 3 exchangeable modules. A set of suction valves and discharge valves are mounted inside each module.

Dampener

Safety Valve

Discharge Filter Holder Anti-shock Pressure Gauge

Discharge Pipe

Elbow Cylinder Assembly

Fig. 2

Structure of Discharge Manifold

The 3 modules are secured on the framework by bolts. Discharge manifold is installed above the cylinder, with discharge outlets at both sides. And a filter can be installed at one side, while an elbow pipe installed at the other side. Pulsation dampener, safety valve and anti-shock pressure gauge can be installed on the elbow pipe. For the
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structure of the discharge manifold, please refer to Fig. 2. a. Module Straight-way type module is adopted, made of forged steel alloy. The fluid flow rates in all the modules are the same, preventing the valve assembly from the influence of the cross flows discharged out of other modules. The valve sizes conform to the API standards. b. Liner, Piston, and Clamp Bi-metal quality liner is used. The inner is made of wearable forged steel, hardness up to HBC 60-65, and the ID surface has high fineness. The liner is variable in several in ID sizes, and the same as the sizes of the piston matching with the liner. Liners and pistons of different IDs are used for different drilling conditions. The piston is consisted of piston core, rubber cup, clamp plate, and snap spring. The piston and piston rod have a cylindrical surface fit, sealed by seal parts, and lock nuts with lock rings used to press tight, which can not only lock the nut after tightening but also seal there between. The piston rod and the pony rod are connected by clamps, has rabbet locating device at the juncture to ensure the axiality. c. Cylinder lid, cylinder lid plug, and cylinder lid flange The cylinder lid flange connects with the cylinder by studs, with the cylinder lid by saw tooth threads. Press inside the cylinder lid plug, which has a central screw hole used to install pull bar to dismount the cylinder lid plug. d. Valve Assembly The suction valve and the discharge valve are exchangeable. The external conical surface with a 1:6 taper engages with the internal conical surface of the cylinder valve seat. The sizes are as required by API 6. 3). Suction Pulsation Dampener and Discharge Pulsation Dampener a. Suction Pulsation Dampener The suction pulsation dampener is installed at the side of the suction manifold, to dampen the suction pulsation to improve the volumetric efficiency.
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b. Discharge Pulsation Dampener Installed at the discharge elbow pipe, see Fig. 2, consisting of housing, bladder, press board and throat flange. The volume and the pressure load capability meet the drilling pump requirements. Nitrogen or air can be charged inside the air dampener, but not combustible gases like oxygen or hydrogen. The maximum precharge pressure of the pulsation dampener is 4.5 MPa (650psi). The stop valve will be closed after charging, to protect the pressure gauge. c. Shear-pin Safety Valve The shear-pin safety valve is installed at one side of the elbow pipe of the discharge manifold, see Fig. 2, to vent quickly once the pump pressure exceeds the predetermined value, so as to ensure the safety of the equipment. Levels of pressures are marked on the shear plate; the pressure is adjusted by inserting the safety pin in different holes. Take care that only 1 pin can be inserted on the pin plate. And this valve must be installed before the stop valve, to prevent the pump from startup before the stop valve opened. 4). Spray Pump Assembly The assembly includes spray pump, water tank, and spray pipe, used to cool and lubricate the liner and piston during the pump running, increase the working life of liner and piston. The spray pump is a centrifugal pump, driven by the driving shaft through belt wheel (or driven by the motor separately). The water is used as the cooling and lubrication fluid. The spray pipe can be mounted on the clamp which connects the pony rod and the piston rod. It can reciprocate with the piston, or fixed at a proper location, to ensure the cooling & lubrication fluid always flush the interface of the piston and liner. 5). Charging System This charging system can be configured as necessary, including charging pump, support base, butterfly valve and manifold. It is driven by a motor, installed at a
8

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

5. Assembly and Disassembly of Main Components

1) Disassembly of Main Components of Fluid End a. Disassembly of Piston Put a round bar into the hole of the cylinder lid, to remove the lid. Then take off the cylinder lid plug, pull out suction valve guide, and remove the clamp connecting the piston rod and the pony rod. And rotate the pump to separate the pony rod and the piston rod. And another bar is forced between the pony rod and the piston rod, and the piston can be pushed out of the liner by turning the pump. The piston then can be taken out of the liner bore of the cylinder. b. Disassembly of Liner and Piston First remove the cylinder lid, lid plug, suction valve, guide and the clamp connecting the piston rod and the pony rod as described above, and then remove the cylinder liner cover plate, and separate the piston rod and pony rod by turning the pump. And then use a copper bar to knock evenly the peripheral edge of the liner to separate the liner from the liner seat, and the liner and piston can be then taken out of the cylinder lid hole at the front of the cylinder. c. Disassembly of Upper Valve Seat Plug a round bar into the valve pot cover hole to remove the valve pot cover, then take out the valve spring and the valve assembly. And then use the hydraulic handling tool provided along to remove the upper valve seat. d. Disassembly of Lower Valve Seat After the upper valve seat removed as above, use the special valve-seat handling tool to take the lower valve seat out of the cylinder lid hole. 2) Assembly of Main Components of Fluid End a. Installation of Module Lift the 3 modules onto the framework, and secure with bolts (not too tight). The modules should keep upright and balanced with each other. Then install the suction
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manifold and discharge manifold. After all adjusted well, use the torque spanner to tighten the connection bolts of the suction pipe, discharge pipe and framework to the module to the required torque value. Note Letai gel shall be applied to the bolts and nuts before tightening. The tightening torques for the bolts are as following.
Pump Cylinder Model

LGF-1000 Thread size 7/8-9UNC-2A 1-1.4-8UN-2B 1-1/2-8UN-2B 1-3/8-8UN-2B Toque (N.m) 298-338 1287-1355 2134-2202 1775-1842

Connection with suction pipe Connection with discharge pipe Connection with the framework Connection with cylinder lid flange

b. Installation of Valve, Valve Seat and Valve Pot Cover Assemble the valve body, valve rubber, and valve nut together. Clean the external conical surface of the valve seat, and make sure no nick or burrs. Then put the valve seat inside the conical hole of the valve pot which is also cleaned already (Note: It is prohibited to apply oil on the external conical surface of the valve seat and the internal conical surface of the valve seat bore.). When assembling the valve seat, its preferable to put an old valve body on the seat and use the iron bar to hammer 3 times and later take away the old valve seat to check whether the valve seat is secured or not. If no old valve body available, a copper bar can be used to knock around the upper edge of the valve seat to seek a tight fit with the cylinder. Note the lower valve seat should be installed before the upper valve seat. Then mount the valve assembly onto the valve seat, with the valve spring at the center of the valve body. The suction valve shall be installed after the liner and piston being installed. Grease the seal ring of the valve pot cover, and install it on the cleaned cylinder shoulder. After the valve pot cover, valve stem guide and the baffle are installed, apply lubrication oil on the threads of the valve pot cover and tighten with a round bar. c. Assembly of Piston and Liner

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When assembling the piston, pay attention to put in O rings between the piston and the piston rod. Otherwise the drilling mud will damage the piston and piston rod. Then can the piston be mounted and piston nuts tightened. The torque value for 1-1/2-OUN-2B nuts is 1625-2165. The piston can be put inside the liner after the liner be mounted on the pump body, or it can be assembled with the liner outside the pump first, and later installed into the cylinder together. The assembly procedure is in reverse to the disassembly procedure. When assembling the piston into the liner, calcium grease must be precoated on the inner surface of the liner and the external surface of the piston. Then the liner seal rings, liner locating tool can be installed. And then the suction valve body, valve spring, valve guide and clips will be installed. And finally the cylinder plug be installed and cylinder lid tightened, and the clamp connecting the piston rod and the pony rod is installed. 3) Disassembly of Main Components of Power End a. Disassembly of Crankshaft z z Take off the clamp, together with the pony rod and its packing box. Remove the left and right crosshead pins, and then the pin at the center of the crosshead (or remove the press board of the central crosshead pin and then dismount the crosshead and the crank shaft together,). z Take off the left and right main bearing caps and the cap at the back. And take off the cap of the main bearing seat. Then the crankshaft can be lifted up with a crane. And the other parts can be disassembled as required. b. Disassembly of Pinion Shaft z Take off the bearing caps at both ends of the framework, remove the main bearing sleeve bolts at either end of the pinion shaft, and take the pinion shaft and the bearing sleeve at the end without bolts out of the bore. The inner race of the bearing is detachable. z If the pinion shaft to be dismounted without the need to disassemble the crankshaft assembly, first support the 2 ends of the crankshaft, pull out the bearing sleeve, making the pinion gear separate from the bull gear, and then pull
11

the pinion gear out of the framework. z If damaged bearings are to be taken out without the need to disassemble the pinion shaft from the framework. The bearing sleeve shall be pulled out, and then the inner race of the bearing is pulled out along the pinion shaft. 4) Assembly of Main Components of Power End a. Assembly of Pinion Shaft Assembly (see Fig. 3)

End Cap

Bearings

Pinion Shaft

Bearing Housing

Fig.3

Structure of Pinion Shaft Assembly

Pinion and shaft belong to an integral machine component. Therefore assembling may be completed after mounting bearings and spacer rings of oil sealings. Note: z Be sure that the packing ring of pinion bearing sleeve and the packing ring of cap are positioned correctly. z When mounting bearing sleeve and cap, the oil grooves on them must be downward and toward discharge hole. z Tighten the bolts on bearing sleeve with torque 190~255 Nm. Assembly of Crankshaft Assembly(see Fig. 4)
Crosshead Bearing Bull gear Pony Rod Eccentric Cam Bearing Main Bearing Main Bearing Cover Bearing Housing

12

Fig. 4

Schematics of Crankshaft Assembly

Assembly of bull gear: z Put bull gear on crankshaft flange. Thoroughly clean the match surfaces of the bull gear and the crank-shaft flange. Then secure the bull gear, tightening all bolts with torque 1055 Nm. z Mount outer races and outer retaining rings of the connecting rod bearings on three connecting rods separately. Draw-off tray must be located just under the working connecting rod. Tighten bolts of the bearing retaining ring with torque 60-90 Nm and lock them with wires. z When assembling connecting rods, the middle one must be installed at first, and locating ring be mounted. z When assembling lateral connecting rods, bolts on the inner retaining rings must be tightened with torque 60-90 Nm. z Mount the crankshaft assembly onto the framework. Before lifting the crankshaft, put wooden supporting block on each of the guides (see Fig.5).
Connecting Rod Upper Slide

Cushion Plate

Lower Slide

Crosshead

Fig. 5

Schematics of Wooden Supporting Block

z Lift the crankshaft and put it into the framework, and then connect it with the crosshead already mounted there. The torque value of 6 1" -8UN bolts is 225-240Nm. Note that the oil catchment ditches of the retainer plates of the crosshead should face upward. The retainer plates at 2 sides should be installed at the outside, while the middle one be installed according to the location of the crosshead pin. z There are 2 methods to adjust the clearance of the main bearing. Calculation method:

Measure the outside diameter of the main bearing housing, A; Measure the diameter of the inner bore of the main bearing seat (or read directly from the end face of the bearing seat on the framework ); The actual thickness required of the support block =0.25-[0.10-(A-B)]mm; Tighten the main bearing bolts, 2-1/2-8UN-2A bolts, by a torque of 11923N.m.
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Test and adjustment method: Insert 0.50mm steel spacer at the binding face of the main bearing cover; Put a lead wire at the middle part of the engagement area between the inside bearing cover hole and the bearing. Tighten the main bearing cover bolts with required torque value; Remove the bearing cover, and measure the thickness of the lead wire; The pre-compression of the bearing cover is 0.10mm; The actual thickness required of the spacer =0.50mm (thickness of the adjustment spacer)-the thickness of the compressed lead wire 0.10mm (pre-compression of the bearing).

Main Bearing Bolt

Main Bearing

Lead Wire

Main Bearing Housing

Bearing Cover

Crank Shaft

Shim

Fig. 6

Adjustment of Main Bearing Clearance

6. Pump Startup after Installation and Running Monitoring

1) Installation a. The mud pump should be installed on a foundation horizontally placed or slightly tilted to the fluid end (at an inclination 3), to ease the flow of the lubrication oil. b. The mud pump should be installed at a level as low as possible, while the mud tank should be placed as high as possible, to improve the suction efficiency of the mud pump. c. The suction end of the pump suction pipe should be 300mm higher than the mud tank bottom, and the ID of the suction pipe must be constant, the suction end of the suction pipe shall not face the inlet of the mud tank. d. Secure all suction and discharge pipelines, to prevent unnecessary stresses and
14

minimize vibration. The pipelines are prohibited to hang around the pump without firm support. 1) Pump Startup a. Preparation before startup z Check the bottom of the framework of the power end. Discharge all lubrication oil if any and clean the oil tank. If the oil has been discharged already, check to see if the tank is clean. Then feed lubrication oil to the maximum level. The lubrication oil used is as following. Season Lube Summer Winter

N320 moderate-extreme pressure N220 moderate-extreme pressure gear oil (S-P type ) plus 10% gear oil (S-P type ) plus 10% 4#antirust compound, or 200# 4#antirust compound, or 120# moderate-extreme pressure gear moderate-extreme pressure gear oil (S-P type ) plus 10% oil (S-P type ) plus 10% 4#antirust compound

4#antirust compound

Open the upper peephole cap of the mud pump, feed sufficient lubrication oil into the oil ditches of the pinion bearing and the crosshead, keeping all friction faces of the pump lubricated before startup. z Check the crosshead clearance. The clearance between the upper crosshead surface and the slide shall not be less than 0.5mm (0.02in.). The clearance of the crosshead can be larger. This is because the working properties of the triplex pump. The load of the crosshead is always exerted on the lower slide during forward running of the pump. While during reverse running, the load of the crosshead is exerted on the lower slide. So the clearance of the slides must be controlled between 0.450.55mm (0.01770.0217in.). z Check the cooling lubrication oil in the oil tank of the spraying pump to see if it meets the requirements. z Tighten all bolts. Check the valve pot cover and cylinder lid to see if they are tightened enough. And check the bolts of the connecting clamp of the piston rod
15

and the pony rod are tightened or not. Take out the supporting block at the crosshead hole to see any unnecessary objects inside the pump or the framework. z Check all valves on the mud lines to see if they are properly opened or closed as required before the startup. z z Check the charging pressure of the discharge air dampener, if reaching 4.5MPa. Open the suction and discharge valves of the spray pump system and the charging system (if necessary). z Check the discharge safety valves and the pressure gauges to see if they are equipped complete and sensitive. z Fill the suction valve pots with water or mud to vent out all air.

b. Startup z Start at a speed as low as possible, and then speed up gradually, so as to improve volumetric efficiency. z When the charging pump is not used, lower the maximum speed of the pump to a value which can keep the pump work normally. If the pump speed needs to be quickened, the charging pump must be used. z Check the readings on the pressure gauges along the lubrication oil loop. If no readings, repair in time. z z z Check temperatures all around, no local overheating is permitted. Operator and inspector should be contacted before pump startup. The inspector must watch the pressure readings on the gauges when the pump is started. The workers cannot leave the air switches before the mud returns to the surface. z When engaging the clutch, 2-time startup method is adopted, which can give a chance for the pump to move, and also can observe if any obstacles exist during pump startup. If all normal, engage the clutch. c. Monitoring the Pump Running z Check to see any abnormal noise in the clamp connecting the piston rod and the pony rod. Check all screw caps on the cylinder and all valve pot cover to see if they are loose or not. Any anomalies found, find the reasons and solve them in
16

time. z Check to see any leakage at high pressure sealing points, any spur leakage at pump valves or cylinder, if any problems found, solve in time. z z z Note variations of pump pressure, solve properly if any anomaly found. Check to see if the water/oil supply to the spray pump normal or not. Check if the temperatures is too high or not at all bearings, crosshead slides and other moving parts. z Check to see if the pressure gauges on the lubrication oil loop of the power end behind the framework work normally or not.

7. Pump Maintenance
Proper and timely maintenance of mud pump is necessary to ensure normal work and a long working life of the pump. Attention should be paid to every pump in this respect when it is in operation. 1). Daily Maintenance a. Check the oil level of the power end after the pump shut down. If it is chain driven, the oil level in the chain box should also be checked. b. Check the running condition of the liner and the piston. Its normal if small amounts of mud leaks, the pump can continue working. If the leakage exceeds the limit, the liner and the piston must be changed. c. Check the liner bore of the framework. If there is large mud precipitation, clean it. d. Check if there is sufficient cooling lubrication oil inside the oil tank of the spray pump. If the oil has been contaminated, replace the oil, the same time the oil tank must be cleaned. e. Check the charging pressure of the discharge pulsation dampener to see if it meets the operating requirements. f. Regularly check the reliability of the safety valves. g. Loosen the connecting clamp daily, turn the piston 1/4 round, and then retighten the clamp again. This will make the piston surface worn evenly, so as to elongate the life of the piston and the liner.
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h. Before tightening the cylinder lid and the valve pot cover, apply lubrication grease to the threads. And check every 4 hours to see if they are loose or not. 2) Weekly Maintenance a. Dismount the valve pot cover and the cylinder lid once a week, remove the sludge and clean, and apply supramoly calcium-base compound lubrication grease. Check the inner sleeve of the valve guide sleeve, if it is worn too much (the clearance between the valve guide stem and the guide sleeve exceeds 3mm), replace it. b. Check the condition of the valves and the valve seats. Replace the seriously worn or pierced valve seats, valve rubber elements and valve seats (the valve bodies will be replaced together when the valve seats are replaced.). c. Check the piston-locking nuts. Replace if they are corroded or damaged (Normally, the seal rings inside the nuts will not lock any more if having been tightened 3 times.). d. Drain off the water through the plug at the drainer cap once a week, till oil comes out. 3) Monthly Maintenance a. Check all studs and nuts at the fluid end. Such as nuts on the flange of the cylinder lid, nuts used to connect cylinder and the framework, and the bolts and nuts connecting the suction pipelines and discharge pipelines. They must be retightened with required torques if found loose. b. Check the seal rings inside the packing box of the pony rod. Replace if found worn. However, they must be replaced once every 3 months at least. Please pay attention to the directions of the oil seals when replacing. See Fig. 7.

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Single-lip Oil Seal Upper Slide

Double-lip Oil Seal

Crosshead pony rod

Fig. 7

Schematics of Assembly of Oil Seals

c. Dismount the filter inside the discharge manifold and clean it. d. Replace the dirty oil in the oil reservoir at the power end and in the oil deposition ditch of the crosshead once every 6 months, and flush the oil ditches. 4). Yearly Maintenance a. Check to see if the crosshead slides got loose or not, if the operation clearance of the crosshead complies with the requirements or not (can be adjusted by adding spacers under the slides). The crosshead can be rotated by 180when disassembling the crankshaft assembly. b. It is recommended to make an overall check of the pump every 2 or 3 years. Check whether or not the main bearings, connecting rod bearings, crosshead pin bearings, and driving shaft bearings are worn or damaged. Replace new ones if it is found unable to be used any more. c. Check the gears. Reassemble both the driving shaft and the driven shaft the other way if it is found seriously worn, use the unworn gear surfaces. 5) Other Maintenance Concerns a. Clean the 25conical surface before mounting the clamp connecting the pony rod and the piston rod. b. The liner seals must be replaced together with the liner. c. Drain all the mud inside the valve pot and the liner after the pump shut down in winters. d. All the check holes or windows of the pump must be covered to prevent dirt or
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sands from mixing with the lubrication oil. e. Only inert gases like nitrogen can be charged in the discharge pulsation dampener. Combustible or explosive gases like oxygen or hydrogen must be inhibited.

8. Troubleshooting
1) Fluid End Problems 1. Readings on the pressure gauge drop. The displacement volume reduces or no displacement. Causes 1. Air got inside the pump due to the inefficient sealing at the suction pipe. 2. The suction filter is completely blocked. Solution 1. Tighten the flange bolts of the suction pipe or replace the gaskets. 2. Shut down the pump, and then pull up the suction pipe to clean the filter. 1. Replace the damaged piston: open the valve pot cover to check if it is damaged or stuck. 2. Check to see if the suction pipe and the valve pot cover have a good seal. 1. Tighten the piston nut. 2. Tighten the cylinder lid. 1. Tighten the valve pot cover. 2. Replace the seal rings. 1. Clean the charging joint. 2. Replace the rubber bladder. 3. Repair or replace the needle valve. Disassemble the filter, clean away the impurities and flush clean.

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

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

3. Violent knocking sounds 1. The piston nut got loose. heard out of the liner. 2. The cylinder lid got loose. 4. Mud leakage found out 1. The valve pot cover not of the valve pot. tightened enough. 2. The seal rings are damaged. 5. The discharge pulsation 1. The gas charging joint is dampener cannot be plugged. charged with gas or the gas 2. The bladder in the leaks out soon after it is dampener is broken. charged. 3. The needle valve is not well sealed. 6. Too much load on the 1. The discharge filter is diesel engine. plugged. 2) Power End Problems Causes

Solutions

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

oil holes. 2. Replace new clean oil. 3. Disassemble the bearings, seek causes and replace if necessary. 1. The crosshead or the guides 1. Adjust the clearance or 2 Knocking sounds are damaged. replace the worn guides. come from the power 2. The crosshead bearings are 2. Replace the crosshead end. worn. bearings. 3. The driving shaft bearings, 3. Replace the bearings. driven shaft bearings or the bearings at the big end of the connecting rod are worn.

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

9. Notes for Storage

1) The mud pump must be sealed up for storage if it will not be used for a long time. 2) Before the storage, the pump must be cleaned thoroughly without any dirty material remaining. Drain, flush and dry up all parts of the fluid end. 3) Drain the machine oil at the bottom of the gear case at the power end, and clean the bottom. 4) Viscous oil shall be applied to the machining surfaces of bearings, crosshead, gears, piston rod, and pony rod. 5) Grease shall be applied to the machining surfaces of all parts of the fluid end. 6) The suction and discharge ends shall be covered with blank plates. 7) The end cap, back cap and peephole cap of the crosshead should be tightly covered.

10. Lubrication Oil and Lubrication Grease for the Pump

1) For lubrication of gears, bearings, and crosshead In winter, 22# hyperbola gear oil (code: HL57-22), or N220 moderate-extreme pressure gear oil (S-P type) plus 10% 4# antirust compound. In summer, 28# hyperbola gear oil (code: HL57-28), or N320 moderate-extreme pressure gear oil (S-P type) plus 10% 4# antirust compound. 2) For lubrication and cooling of liner and piston, fresh water is used. 3) Supramoly calcium-base compound grease is used for lubrication of threads. 4). Calcium-base grease is used for piston and liner.
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11. List of Supplied Special Tools

NO. Drawing No. Descriptions Materi al Qty. Unit Total weight weigh t 1.34 1.34 1.5 1.7 2.0 0.38 1.6 2.35 1.5 1.7 2.0 0.38 1.6 2.35 Note

1 2 3 4 5 6 7

LGF3101-25.01 LGF3101-25.02 LGF3101-25.03 LGF3101-25.04 LGF3101-25.05 LGF3101-25.06 LGF3101-25.07

Sleeve 2 Sleeve 2-3/16 Sleeve 2-3/8 Sleeve 3-3/8 Joint 1 Extension bar 8

35CrMo 1 35CrMo 1 35CrMo 1 35CrMo 1 35CrMo 1 35CrMo 1

Extension bar 24 35CrMo 1

8 9

LGF3101-25.08.0 0 LGF3101-25.09.0 0 LGF3101-25.10.0 0 LGF3101-25.11.0 0 LGF3101-25.12 LGF3101-25.13 LGF3101-25.14 LGF3101-25.15 LGF3101-25.16.0 0

Liner plug puller welded Valve stem guide handling tool Liner retainer puller Hydraulic valve puller Transition taper sleeve Compression sleeve Sleeve 1-1/2 Sleeve 1-5/8 Long 1-5/16 welded

1 1

2.5 0.81

2.5 0.81

10 11 12 13 14 15 16

welded welded

1 1

2.7 73.4 1.21 2.74 0.85 0.95 7.45

2.7 73.4 1.21 2.74 0.85 0.95 7.45

35CrMo 1 35CrMo 1 35CrMo 1 35CrMo 1 1

sleeve Q235A

12. Recommended Order List

No. Drawing No. Descriptions Qty. Note
22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

LGF3101-05.17.00 LGF3101-05.17.05 LGF3101-25.22A LGF3101-25.22A LGF3101-25.22 LGF3101-25.22A LGF3101-25.22 LGF3101-25.22A LGF3101-25.22 LGF3101-25.22A LGF3101-25.22 LGF3101-05.22.19.06.00 LGF3101-05.22.19.05.00 LGF3101-05.22.19.04.00 LGF3101-05.22.19.03.00 LGF3101-05.22.19.02.00 LGF3101-05.21 LGF3101-04.09 LGF3101-05.18.00 LGF3101-05.04 LGF3101-05.09 LGF3101-05.20 LGF3101-04.18 LGF3101-27.03.00 LGF3101-28.11 LGF3101-28.03.00

Valve assembly (API 6 6#) Valve rubber (API 6#) 6 3 Liner 6-1/2 Liner 6-1/4 Liner 6 Liner 5-1/2 Liner 5 Piston 6-1/2and rubber Piston 6-1/4and rubber Piston 6and rubber Piston 5-1/2and rubber Piston 5and rubber Piston rod Pony rod Piston nut Liner seals Valve pot cover seals Piston seals Double-lip oil seal 4.55.50.5 Air bladder Shear pin Piston assembly 3 3 3 3 3 3 3 3 3 3 3 6 12 6 6 6 1 12 2

common Common Bi-metal Common Bi-metal Common Bi-metal Common Bi-metal

For piston For pony rod For KB-75 air dampener For shear pin safety valve For shear pin safety valve

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

13. List of LGF-1000 Drilling Pump Drawings Provided

No. 1 Drawing No. LGF3101-00 Descriptions LGF-1000 pump Copies Page drilling 1 4 Notes Assembly chart
23

2 3 4

LGF3101-05.00 LGF3101-27.00 LGF3101-28.00

Fluid end assembly

2 1 1

KB-75 pulsation 1 dampener JA-3 shear pin safety 1 valve

Assembly chart Assembly chart Assembly chart

14. List of Spare Parts

No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 GB/T3452.1-1992 Descriptions Qty. 3 3 3 3 3 3 1 2 3 6 6 3 6 3 3 1 2 2 3 0.6 0.1 0.1 0.32 0.1 0.25 1 0.001 4 0.15 0.45 0.8 1.2 0.3 0.6 1.92 0.3 1.5 3 0.003 4 0.3 0.9 2.4
24

Unit Total weight weight

O seal ring 1753.55 GB/T3452.1-1992 O seal ring 1407 GB/T3452.1-1992 O seal ring 97.53.55 GB/T3452.1-1992 O seal ring 1857 GB/T3452.1-1992 O seal ring 3457 GB/T3452.1-1992 O seal ring 1155.3 GB/T3452.1-1992 O seal ring 1657.0 LGF3101-03.08 Oil seal 8.510.50.625 LGF3101-04.06 Oil seal ring LGF3101-04.18 Double-lip oil seal 4.55.50. 5 LGF3101-05.04 Liner seals LGF3101-05.09 Valve pot cover seals LGF3101-05.17.05 Valve rubber (API 6#) LGF3101-05.19.06.02.00 Piston rubber 6-1/2 LGF3101-05.20 Piston seals LGF3101-05.29.01 Air bladder (suction ) LGF3101-09 Seal gasket (back cover watch hole) LGF3101-22.06 Gasket ring R27 LGF3101-23 Gasket ring R44

20 21 22 23 24

LGF3101-27.01 LGF3101-27.03.00 LGF3101-28.03.00 LGF3101-28.06 LGF3101-28.11

Gasket ring R39 Air bladder (discharge) Piston assembly Cushion gasket Shear pin

1 1 1 1 10

0.65 11 0.057 0.1 0.022

0.65 11 0.057 0.1 0.22

25