MC technologies Model No. Owners Model W11 5262010 Industrial Pump ManualSection A Safety Instructions Accidents occur every year because of careless use of industrial equipment. You can avoid hazards involved with high pressure pumping operations by following these safety instructions. Always use a pressure gauge when operating pump. The pressure must not exceed specified 1000 PSIG or pump casing could be damaged causing leakage, resulting in injury to personnel in vicinity, Do not adapt relief valves to maintain more pressure than their specifications state. This could result in relief valve or pump casing bursting due to too much pressure. Personnel in general area could be physically harmed. Do not put a valve between the pump and reliet valve. If the pump should be started with this valve closed this could put excessive pressure on the Pump which could cause the pump case to burst and might injure personnel or other equipment in vicinity. Be sure to use shields or covers on pumps used for pumping hot water or chemicals. This precaution can prevent service personnel from being burnt by hot water or exposed to chemicals when leaks might occur. Be sure to use shields or covers on all sheaves, belts, and drives. Guards can prevent personnel from becoming seriously injured by being entangled in fast rotating parts. Always disconnect pump from power source before performing any service to the pump. Failure to do this could cause electrical shock or injury from moving pump parts. Always relieve pressure on the system before removing the suction or discharge chamber. Failure to do so may spray water or chemicals on service personnel causing water burns or chemical, exposure, Use extreme care when using solvents to clean pump and pump parts. Most solvents are highly flammable. Odserve all safety instructions on packaging. Fires could result in serious burns to personnel and serious damage to equipment. Do not modify the pump to function beyond its specifications. AlNMC rechnolagies Table of Contents A. Satoty .. B. Specifications . C. Installation Storage Before Installation . . ssid Selecting Pump Location ....... cA Securing Pump to Foundation cA Installing Suction Line... Installing Discharge Line D. Operating Procedures Check Points Before Starting pre Selecting Operating Speed... + D2 Selecting Operating Pressures D2 Starting the Pump D3 Priming the Pump D3 Shutdown During Freezing Temperatures. . .D-4 E. Maintenance Maintenance Procedures. E41 Periodic Maintenance Procedures .........E2 F. Service Step by Step Service Procedures Ft Troubleshooting Ghart......... FA6 Ordering Parts 28 FAD Parts List . sieaneeamaiery tia G. Accessories and Packages so GH To Our Customer We at FMC would like to express our appreciation in your decision to use one of our industrial pumps. This pump was designed by experienced engineers and built by skilled workmen to provide you with quality equipment. FMC stands behing all its products. The warranty on your pump is printed on the back of the Delivery Report. Be sure your dealer has you sign Delivery Report and supplies you with a copy.A v Model W11 q ane yyeneyowonance | eet | l ie ST ee th yo ee | Tet toe H T * Tt Pee fee HE op cn English Metric writes | wiit6b | w1i228 | wi1220 [| wit18B | witied | wi1228 | wi1220 No. of cyl. 3 3 3 3 3 {3 3 Bore; cyl 2a vu" | 2%" Simm | S%mm_| 68.amm | 689mm Siro am" | 2m" | Me 69.9mm | 6.9mm | 6.0mm | 69.9mm Capacit GpM_| GPM | GPM tem [tem | cpm [LPM Min. 14 14 20 53 53 76 76 Max 25 35 37 95 132_[ 140 [789 Discharge pressure PSI Psi_|_ PSI KPA_|_KPA_|_KPA_|_KPA Inter. 700__| 1000 | 1000 695 | 6085 | 6885 | 6895 Input shaft RPM Rem | APM | APM rem | ppm | RPM | RPM Min 350 350] 350 350_| 360 | 360 | 350 Max 635, 690 630 635) 690 630 | ‘Shaft diam. ve" |e” |" [aa YP 3emm_| 38mm | 38mm | samm Crankcase cap dais | dats. | sats | aats. | a7 | 37 | 37 | a7 Lubrication oil s. A. E. 30 Inlet opening diameter 2ner | 2ner | 2net | 2ner || 2NeT | 2NpT | 2NPT | 2NPT Outlet opening diameter 1% NPT | 1% NPT] 1% NPT | 1% NPT|| 1% NPT| 1% NPT|1% NPT] 1% NPT Max. fluid Temperature seorF_| 160°F | 160°F | toorF || rico | ziro | rire | rire Dimensions inches_| inches | inches | inches || MM. | _MM. | _M.M. | _M.M. Height 14" 14” 14" 14" 36cm | 36cm _| 36cm | 36cm Width our | aou" | aou" | 20%" || Siamm | Stamm | Stamm | 514mm Length 23" ze" | 29" | 29" || 730m | 730m | 730m | 73cm Weight 425 ibs. | 425 Ibs. | 425 Ibs. | 425 Ibs. [| 193 Kg | 193 Ka. | 193 Ka. | 103 Ka. B-1FMC rechnologies Section B Specifications Model W11 Industrial Pump Description ‘The W11 is a high pressure triplex piston pump Gesigned for long life in demanding industrial ‘operating conditions. All pumps in these lines utilize durable, high quality materials such as ceramics and hardened stainless steel to minimize ‘wear and corrosion of critical components. The disc valves are stainless steel and give maximum volume and quiet operation with a free flowing liquid. Stainless steel ball valves provide positive sealing by line contact for viscous liquids with small or suspended solids. Ceramic cylinders are standard on all W11 pumps. The drive end features @ pump case made of SAE G3000 cast iron. The casting is internally ribbed for added strength and the crosshead guides are machined as an integral Part of the crankcase. Both the crankshaft and the ring gear are made of drop forged, fine grained alloy steel. The ring gear is precision machined ‘and shrink fitted to the crankshaft — for positive alignment and concentricity. Crankcase — totally enclosed design, iron alloy casting, adaptable to right or left-hand drive, oil bath. Connecting Red — Ductile iron split cap design, with shell type bearing inserts. Crossheads — Cylindrical design cast iron with stainloss stool crosshead rods. yankshaft — Drop forged steel with induction hardened bearing throws and helical design gears. Valve Chamber — Cast iron. Cylinders — Non-wearing alumina ceramic. Valve — Two types: stainless steel, spring loaded disc valve; stainless steel ball valve. Piston Cups — Nooprene and fabric or Carboxilated Nitrile and fabric.FMC Technologies Section C Installation Procedures Storing Before Installation Your FMC pump will come to you prepared for any necessary Storage periods hefore installation. Selecting Pump Location Always locate the pump as close to the source of supply as possible. The pump should also be located in a light, clean, dry space where adequate inspection and maintenance operations can be pertormed. ‘Securing Pump to Foundation Locate the pump so the power will turn the top of the pump sheave away from the fluid ond of the pump. Align the power source drive sheave and pump sheave. To check tho | alignment, use a straight edge, square or tule. Place the straight edge against the sides of the sheaves to be sure they are in line and running exactly parallel to each other. NOTE: Proper alignment of the drive sheaves is very important to prevent excessive pump bearing and V-belt wear. 3._| Mount the pump on either a concrete or rigid metal-base using the mounting ‘supplied with the pump and %" bolts. (Use shims, to level the pump if necessary, to prevent straining the pump case.) Secure the pump to maintain alignment and to prevent vibration.Installing the Pump Suetion Line Procedures Determine the shortest most direct route possible fr the suction hose. fake @ preliminary design of suction piping, Remember the line shouts be as 0 NPSH CURVES MODEL Wit large, direct, and short as possible. | NOTE: Line must be laid out so there are no high 1 spots to cause air pockets. Any air pockets in the Biz line could make priming the pump difficult or x 6 impossible. = 3. | Analyze the Net Positive Suction Head 8 4 Wi 1228, that would be available In your 8 preliminary design. The NPSHA (Net ‘ Positive Suction Head Available) is a 14 characteristic of your pumping system a | determined by: 10 4 a. The elevation of the suction supply 9 MeOH TSB: in telation to the pump suction port a (static head) ; NOTE: Static head is (+) plus when liquid is above 6 the pump’s center line, and (-) minus when liquid 200 «00 400 500600 is below (or suction lift) RPMPNON b. Altitude of the installation above sea level (atmospheric head) . Friction in suction line (friction loss) 4, Liquid vapor pressure (vp) e. Amount of suction head required to. accelerate fluid in the suction pipe to prevent cavitation (acceleration head) NOTE: NPSHA = = static head + atmos. head- friction loss-acceleration head-VP. 4 | Compare available NPSH with required NNPSH tor your pump at your particular RPM requirements. NOTE: There must be at least two additional feet of NPSHA over the required NPSH to compensate for variations in atmospheric pressure and other similar variables. 5 | After determining the correct suction line for your required needs install the line. The suction line should be supported independently of the pump. Install a union as close to the pump as. possible, to allow for easy removal of the valve chamber during servicing, NOTE: It is advisable to use a flexible connection Such as a hose between the hard pipe and pump suction opening to isolate vibrations. NOTE: Be sure all parts are free of dirt, scale, burrs, or other foreign material which might interfere with pump operation.FMC rechnologies Installing the Pump Suction Line (Continued) Procedures install a foot valve when there is suction lift. The foot valve should be installed in the suction line near the fluid source. The foot valve will keep the lines to the pump filled and avoid the necessity of priming at each start. Ifthe supply of liquid is delivered from pressurized line or through rigid pipe, itis advisable to install a suction line air chamber close to the pum} to reduce the possibility of water hammer. On pressurized suction lines an accumulator should be used and pre. charged to 2/3 of the maximum anticipated suction prossura. Install drain plugs or drain cocks in low points of suction lines. NOTE: This is highly important where temperature conditions are below freezing. 9 | Install suction strainer (2) in the suction line to remove particles that could ‘damage internal pump components. NOTE: Use only full opening gate valves for minimizing flow restriction. 10. | Make sure all joints are air tight. NOTE: Air leaks reduce pump capacity and cause cavitation. Vi 1. Air Chambor 2. Suction StrainerInstalling Pump Discharge Lines Determine the shortest most direct route for the discharge line. Determine the length of hose or pipe required and determine the size of the hose or pipe by considering pressure loss per foot of hose required. Select weight of pipe required to meet Pressure requiraments from adjacent Chart. Hose ratings ate clearly marked on outer surtace of hose. WARNING Always use hose or pipe that is designed for your parcicular pressure requirements. Inadequate hose could burst resulting in possible personal injuries and equipment damac Install pipe or hose to pump. Is advisable to use a flexible connection the pump and the rigid pipe (if used) and the discharge opening to isolate vibrations and to allow for easier service. NOTE: 1@ sure all parts are free of dirt, scale, burns, or other foreign material which might interfere with pump operation. 5 Install the pressure gauge onto the discharge chamber. The pressure gauge will indicate the fluid pressure so that pressure can be adjusted to the proper level.(1) Install the relief valve onto the discharge chamber. (2) Install the relief valve by-pass. If the {luid is drawn from a tank, the relief valve by-pass should be returned to the tank. The flow may be returned to the suction line (when other means of return are not possible) if it is returned into the line a far as possible from the pump to reduce the possibility of turbulence and cavitation in the suction ine. NOTE: The reliot valve by-pass line must be as large as the pipe outlet in the relief valve. Never install vi /alves in the bypass line or between the Pump and relief valve. Optional] 8 ‘A pop-off valve may be used in the discharge line to limit the pressure. However, provisions should be made to dotect leakage past the valve. Optional 9 A discharge pulsation dampener may be Installed to absorb pulsations, pounding and prevent water hammer. It should be installed very near the pump. Bladder type pulsation dampners should be pre- chartered to approximately 213 of the maximum anticipated pump pressure. Pipe pressure chart Pounds per square inch For cold water, minor shock conditions Working Pressures ‘Seamiees Stee! Pipe ‘But Welded Pipe TASTM R120 ASTM AT20. roe we | eo Oost Pete 41. Pressure Gauge 2. Reliet Valvo 3. Pulsation DampenerFMC rechnologies Section D Operation . Check Points Betore Starting — Always make the following checks before starting the pump. Make sure the magnetic drain plug (4) in the bottom of the pump case is tight. ‘Check the oll by means of the petcock if necessary add a good grade of SAE 20 weight oil through the filler opening (1) NOTE: The oil should come up to the petcock (2) fon the back of the drive end. 3 | Inspect the entire pump installation to make sure all the joints are tight. 4 | Apply grease to the 3 grease fittings (3) and regrease every 2000 hours or twice a year. NOTE: Grease with a good grade of water resistant Grease. (Refer to Lubrication Procedures.) 4. Filler Cap 2. Petcock 3. Grease Fittings 4. Drain PlugHORSEPOWER CURVES MODEL MOS wae Selecting Operating Speeds paren The capacity (gallonage) in a positive displacement pump, suchas the Wit is determined by the RPM of the crankshaft, To achieve the proper capacity desired, select the capacity on the chart then go up and find the RPM Fequired to produce that gallonage, Selecting Operating Procedures The pressure can be adjusted to the required value by adjusting the relief valve nut. CAUTION Do not run the pump beyond the rated pressure or the maximum rated RPM. Exceeding the pump ratings wil result in reduced pump Ife and could cause damage to the motor and piping. To determine the proper horsepower required to run at a specific pressure producing the required gallonage refer to the chart. lwiz2ruye [2 ae x Denne D-2FMC rechnologies Starting the Pump - The following procedures should be followed when starting the pump for operation, Procedures 1 | Open the gate valve in the suction line. ha The gate valve must remain fully open operation of the pump. Check to assure power is off. 3 | Tur the pump over by hand to make sure the crankshatt is free. WARNING Never try to turn the pump over when the power is on. Service personnel could be entangled in moving sheaves. Fill the suction line with fluid, if necessary to prime pump.(2) Start the pump, and for a few seconds listen for erratic noise or for unsteady flow which indicates the pump is not primed. Never run the pump over 30 seconds not If flow is not continuous (pulsing) shut the pump off and prime. Priming the Pump - The following procedures should be followed for priming the pump. Steps | Procedures 3. Discharge Portion of Valve Chamber 1 | Fill the suction line and filter. 2 | Remove the accumulator or the pressure gauge by unscrewing, 3 | Fill the discharge portion of the valve chamber with fluid.) 4 | Jog the pump until the fluid is pumped from the discharge ports in a steady, ‘even flow. 5 | Reinstall the accumlator or pressure gauge. 6 | Start the pump and listen for unsteady flow of erratic noises. If unsteady flow persists repeat steps 1-6 until pump is properly primed. 7 |i pump continues not to prime check the plunger packing _ to see if there is excessive leakage through the packing. Should the packing be leaking 15 to 20 Grops per minute shut the pump off and replace the packing. (Refer to Service, Section F)Shutdown Procedures During Freezing Temperatures The following procedures should ve followed when ——_| stopping or storing the pump during free: weather, | - | Procedures Let the pump pump air for a few seconds with the discharge outlet and suction line open. This will flush the valves and discharge lines. NOTE: When pumping liquids that cannot be contaminated by using a diesel fuel, pump diesel fuel through the system. By doing this, you will eliminate the need for steps 2-12. WARNING Do not use this procedure when pum lids that can bo contaminating by having diesel fuel in the pump or suction and discharge line: Shut the pump off. Relieve pressure on the reliet valve by turning the top of the valve counter- clockwise(1). WARNING Failure to do this could cause fluid to shoot out when discharg Al manifold is possibly spls ; | Remove plugs from under the suction valve area of the valve chamber. 1. Rellet Valve 2. Hex Nuts 3. Cover Clamps 5. Drain Plugs D-4¥ MiG technologies ‘Shutdown Procedures During Freezing Temperatures. cont'd NOTE: FMC recommends lubricating bolts before replacing nuts. Remove the six hex nuts and the three clamps from the cylinder chamber. Slide the cylinder cover from the valve | chamber. Drain all trapped fluid from inside the | valve chamber by lifting the suction valve with the end of a wooden nail or serewdriver. Coat the valve cover with a rust preventative agent. Replace the valve cover clamps and nex head nuts Torque the hex head nuts in the ‘sequence shown on pago 0-4. Torque comer nuts and cylinder cover nuts to 904t. Ibs, Replace drain plugs in valve chamber. Ia drain plug is used under relief valve, remove plug. Remove drain plugs in all low points of piping. Leave all cutotts open. D-5Jue Oy HOV OW ©) SOO TORQUE SEQUENCE FOR CYL. COVERS & CORNER STUDS. TORQUE SPECIFICATION CONNECTING RODS 65 FT. LBS. BEARING COVERS 50 FT. LBS. CYLINDER COVERS 90 FT. LBS. VALVE COVERS 60 FT. LBS. [PACKING NUT ASy | 35 FT. LBS, REAR COVER 15 FT. LBS.FMC technologies Section E Maintenance Procedures Lubrication The W11 pumps require four quarts (3.7 liters) of grade SAE30 lubricant in the crankcase. After the first fifty hours of operation, drain oil trom the crankcase and remove any metal adhering to the magnetic drain plug. Thereatter, at the end of each 750 hours of operation, the oil must be drained and the drain plug (4) shouid be cleaned of any metal adhering to it. Should oil have a milky appearance, this indicates water is leaking past plunger rod seals in the pump. The plunger rod seals should be checked and replaced if necessary. After draining all oil, replace the drain plug and add the oil through the oil fill opening (1). Add oil until level with the petcock (2) on end of pump. Filling oi past this point will damage seals. Another area of the pump requiring lubrication are the fittings on the plunger oil seal holders. These fittings should be greased once yearly (3) CAUTION Do not overgrease fittings to the plunger oil seal holders or damage could occur to oil seal and holders. Filters should be installed in the suction line to prevent contaminated material from entering the pump and reducing its life and efficiency. During the initial break-in period, the pump filter screen should be inspected frequently. The amount of material trapped in the filter during these inspections will indicate now often the filter, screens should be checked a regular inspection schedule should be developed from this informationPeriodic Maintenance Chart ‘Always read your operator's manual thoroughly before performing any maintenance on the pump. Pump Filter Screen removing plug. Clean any metal adhering to plug betore replacing. Refill pump case with new oil. ‘Should be Inspected frequently to determine a regular inspection schedule. Components Description of Service Remarks Break-in Period Crankcase Drain oll from crankcase by Atter the first 200 hours of operation: ‘The amount of material collected in the filter with each check will Indicate how often the filter should be inspected. ‘Components Description of Service Remarks Daily Complete Pump Plunger Rod Oil Seals Packing (Plunger) Pump System General inspection of pump in operation to determine if it is functioning properly. Inspect plunger rod oil seals for leakage. Inspect packings tor leakage. Use water or a suitable solvent and flush the entire system. This inspection should take place once each shift of operation. Leaking at the rate of one or two drops per minute indicates the need for replacing the oil seals, {fefer to Servicing Oil Seals, page 1) Excessive dripping at this point indicates worn plunger packing. Adjust or replace as necessary. (Refer to Replacing Plunger Packings, page F-3) For overnight shutdown when using materials that might harden or corrode the pump. Drain all water from pump chambers and piping when freezing temperatures are anticipated.FMC technologies Periodic Maintenance Chart - Cont. Components Description of Service Remarks Weekly Crankcase NOTE: Do not over-fill, oil will run out oil fill opening when too full Check oil level in crankcase by opening the petcock on the end of the pump. With pump stopped, oil level with petcock opening indicates proper il level. plug. Components Description of Service Remarks Every 2500 Hours (equals 31% months of continuous use) Crankoase Change oil and clean magnetic | SAE 30 grado, Long Term Storage Pump System Drain Pump (Reter to page D-3, Storing Pump During Freezing Weather.) During treezing temperatures. E-3FMC Technologies Section F Service In this section we will cover how to service the pump. The first portion will cover step-by-step procedures for servicing the different areas of the pump. Then at the end of this section you will find a quick reference troubleshooting chart. Servicing the Fluid End Servicing the Valves - Maitunctioning valves are identified by a uniform hammering or vibration and by reduced pump capacity (volumetric etficiency), 10 [steps Procedures WARNING Always disconnect pump from power source before performing any service to the pump. Failure to do this could cause electrical shock or Injury from moving pump parts. Remove all plugs in discharge or suction inlets, Remove the six nuts on the studs.(1) Slide the three cover clamps off the studs(2) Slide the three valve covers from the valve chamber. Place the valve seat remover tool (FMC 41285079) or a blunt rod against the ‘suction valve seat and by using a hammer, drive the suction valve seats Ioose.(4) Remove the valve through valve cover ‘opening. Remove all three suction valves in the same manner. Insert the blunt tool through the ‘opening for the suction valves and position against the discharge valve seat. Using the hammer, drive the discharge valve out the chamber discharge ‘opening. Repeat until all dischare valves are removed. Removing Valves.NOTE: The complete valve assembly is available for easy and quick servicing of the pump, or individual valve assembly parts are available. (Refer to parts list, page F-20.) 12 Complete vaive assemblies can be replaced or just the individual damaged parts. To check the parts of the disc valve, remove the snap ring with a pair of snap ring pliors. This and step 13 are ot necessary for ball valves. 13 | Once the snap ring nas been removed the vaive parts may be easily removed and inspected for damage. 14 | Check that all surtaces on the valve are | free from nicks, burrs and dirt and are | dry. Repiace any necessary parts NOTE: If all valves show wear, replace all valve assemblies to prevent down time during critical periods. Valve kits are available which contain 6 valve assemblies, 3 cylinder nead gaskets, and 3 valve cover gaskets, 45 | Reassemble the valve parts in the order shown in the illustration and photo, | making sure the disc on the dise and | spring assembly is positioned level in the seat. 16 | Check that the spring and disc assembly work frocly in the disc valve, ani the ball moves freely in ball valves; if not reassemble. Insert suction valves squarely in the suction valve openings through the valve cover openings.(1) WARNING Incorrectly installed valves could result in severe damage to the pump and/or injury to personnel. Use a dowel approximately the diameter of the valve and drive the valve firmly in the valve chamber Insert discharge valves through the discharge opening so the snap ring or ball is toward the outside of inlet openings.(2) Drive the discharge valves firmly in Place as in step 18. Inspect the gaskets on the valve cover; if damaged replace. Carefully replace valve covers taking care not to damage gaskets (3) Replace valve cover clamps Replace six nuts and torque to 60 ft lbs. O s—>| Ball ValveFMC Technologies Replacing the Plunger Packings Plunger packings must be replaced whenever the leakage around the packings affects the pump’s efficiency. Packings is normal and is actually desirable to help cool and lubricate the packings. However, leakage of 15-20 drops per minute indicates worn or damaged packings. To change, follow tho steps isted below: ‘A small amount of leakage past the Procedures WARNING ‘Always disconnect the pump from the power source before performing any service to the pump. Failure to do so could result in electrical shock or injury from moving pump Parts or drive parts. Check the corner nuts on the valve chamber to assure that they are at 90 ft Ibs. Remove the six hex nuts(2) on the front, of valve chamber. Slide the three cylinder cover clamps(a) from the valve chamber. Remove the three cylinder covers. It may be necessary {o tap on the sides of the covers to free them from the chamber. Inspect gaskets(6) on the cylinder covers. If damaged, replace with new gaskets. Insert a socket wrench into the valve chamber onto the hex nut(6) in the valve packing. Turn the wrench to the left and remove the nutReplacing Plunger Packings (Continued) steps | Procedures | Insert the packing removal tool (FMC part no. A5049) into the plunger out While rotating the tool to the right, pull the packing assembly from the cylinder | and out through the valve chamber. | Place the packing holder in a vise. Now rotate the nut to the left using the FMC | packing tool. Remove the old packing from the | packing holder and replace with now packing. Then reinsert packing washer ‘and plunger nut into packing holder and reassemble packing nut. Pump should be rotated by hand to bring the crosshead to the front of the cylinder before installing the packing, This will reduce the distance the Packing must be driven into the cylinder and minimize the chance of damage or misalignment. Inspect the o-ring on the end of the plunger rod and replace if necessary. Packing assembly can now be installed with one or two sharp raps against the tool with a 24 oz, or heavier hammer. If installation is not accomplished by two or three blows, further soaking and/or lubrication is necessary. NOTE: Packing kits are available which contain three sets of packings, three cylinder head gaskets, and three plunger o-rings. Part numbers ot kits are: W1118B & W1116D-5256569, W11228 & W11220-5256590.FNC technologies Replacing Plunger Packings (Continued) Procedures Replace the nut in the packing nut with a socket hand wrench by turning to the right Replace the cylinder covers and cylinder cover clamps. Place hex head nuts in the sequence shown and torque 90 ft. Ibs. Servicing the Cylinders Excessive wear of packings may be due to buildup inside ceramic cylinders. Coramic cylinders may De removed and cleaned. To clean cylinders, follow the steps listed below. It is virtually impossible to wear out a ceramic cylinder under normal service conditions, however, they are quite brittle like al! ceramic materials and can be cracked or chipped if ‘subject to mechanical impacts or severe thermal shock. Caution should be used when changine from hot to very cold fluids via fast acting solenoid valves. In the event the cylindor is cracked, broken, or needs cleaning, the cylinder can be easily ‘changed or cleaned by following the steps listed: Procedures WARNING Always disconnect the pump from the power source before performing any service to the pump. Failure to do this could result in electrical shock or injury trom moving pump or drive parts. | Follow steps 1-5 for changing the plunger packings (refer to page F-3) Disconnect the suction and discharge piping from the valve chamber. F5Remove the two corer holddown nuts and slide the valve chamber off the studs. NOTE: Leave the packing in place to retain the cylinders while the valve chamber is being ceramic removed. 4 NOTE: Ct Remove the crosshead rod nuts and then remove the cylinders. The packing assembly can then be pushed out of the oylinder, To clean build up from cylinders, submerge the cylinder in uncut muratic acid (28% hydrochloric acid) for 3 minutes. Then rinse in clear water and wash with a strong soap. Submerge the cylinder in the acid for two more minutes and rinse in clear water and wipe off heck oil seals at this point once cylinders are removed and if necessary, replace. To replace, follow procedures listed under changing oil seal. CAUTION When removing the valve chamber and removing the cylinders, be careful and avoid striking th cylinders against a sharp object as they will chip or crack. Replace gaskets on each end of the cylinder (1) Follow steps 6-14 for replacing plunger packing (refer to pages F-4 and F-5) Insiall the valve chamber cover and tighten the two corner nuts to / the specified torque. (45 ft. ibs.) CAUTION Take care when repositioning valve chamber and tightening nuts not to put cylinders in a bind or bump with a sharp object; damage could occur to ceramic cylinders. F-6FMC technologies Servicing the cylinders - cont'd Replace the cylinder covers, cylinder clamps, and clamp nuts and tighten nuts until they are tight, Then tighten nuts to } of the full torque in tho sequence indicated in the illustration (45 ft, Ibs.). Then repeat tightening sequence bringing to full torque (90 ft Ibs ). This should indicate the two corner nuts. After one to two hours of pump operation, check torque on the clamp nuts and if necessary, tighten again. Servicing the Plunger Rod Oil Seals These seals retain oil in the pump case and prevent dirt and fluids from entering the case by way of the plunger rods, Oil leakage around the plunger, dirt on the case, or milky colored oil are signs of worn or damaged crosshead seals. The seals may be replaced without disassembly of the drive end; however, the fluid end must be disassembled. To change the seats, follow the stops below. [Steps | Procedures WARNING Always disconnect the pump from the power source before performing any service to the pump. Failure to do this could result in electrical shock or injury from moving pump parts or drive parts. | Break down the fluid end of the pump following the steps listed under | servicing the cylinders. 2 | Once valve chamber and cylinder packings have been removed, remove the cover at the pump separation chamber by removing the two screws. TIGHTENING SEQUENCE F-7Servicing the plunger rod oil seals - cont'd Procedures Insert @ large screwdriver into the ‘opening under the separation cover. Using the screwdriver, rotate the oil geal nut to the left until it is unthreaded from the pump case.(1) Remove the oil seal sleeve and oll seals from each plunger rod opening. Slide the sleeve and oil seals from the plunger rod using a simple hook-shaped tool. NOTE: It is never advisable to reuse oil seals which have been removed from the pump. 5 The new outer seal must be positioned in the sleeve so that the lip on the seal faces the valve chamber. Position the seal into sleeve until it bottoms out, Replace the inner seal so the lip faces. the drive end of the pump. 6 | Pack the area between the seals inside the sleeve with a Dow coming valve seal “A” before installing them in the pump. 7 | Position a piece of thin walled tubing, ground to a thin edge, or thin shim | stock or piece of heavy paper rolled in a tube inside the seal. This will protect | the lips on the seal while passing them | over the plunger rods. Now slide the | sleeve and seals with the protection | Bla a tubing oF paper over the rod | and into the case. CAUTION Care must be taken to avoid folding the lip under when the seals are passed over the end of the plunger rods, Failure to do this could damage seals resulting in leakago around seals. Once sleeve and oil seals are in place on plunger, replace oil seal nut and tighten. Replace the fluid end parts by repeating steps found in Servicing the cylinders.FMC technologies Servicing the Drive End Servicing the eccentric shaft and connecting rods; these components seldom need servicing of replacing unless the pump has been run without il or with severely contaminated oil. Problems with the shaft and rods will be indicated by knocking noise or excessive pump case temperature. Procedures WARNING Always disconnect pump from power source before performing any service to the pump. Failure to do this could result in electrical shock or injury from moving pump parts or Grive end parts. Disconnact piping to valve chamber. Remove the pump from its mounting and place on a bench or other convenient place for servicing the power end. Place container under the drain plug in the drive end and remove the drain plugs and drain all oil from the drive end. Also position a couple of 2x4’s under the drive end of the pump. Remove the 8 nuts on the studs. Slide the 3 cover clamps off the studs. Slide the 3 valve covers from the valve chamber. Remove the valve chamber trom the pump. Follow steps 6-20 for changing the valves (refer to page F-1). NOTE: To prevent unnecessary down time, valves, packing, and other wear areas should be changed while breaking down the pump. ‘The packings must now be removed. Follow steps 5-9 (page F-3, F-4) for changing packing. F-910 n 12 13 14 15 16 7 18 19 20 2 Procedures Pull the cylinders. Leacom tne oll seal nu refer to page 7), Remove the oil seal sleeve and oil seal (refer to page F-7). Remove the capscrews, washers, cover and gasket from the power end of the ump. jemove the three Ye"-19x1% Capscrews, pinion bearing covers and gaskets at each side of the pump case. Use a wood block and hammer to drive the pinion shaft trom the pump case if pinion shaft or bearings need replacing. Use a press and suitable blocks to press the bearings from the shaft. (Steps 15 & 16 may be omitted if the pinion shaft or bearings do not need replacing.) Remove the ¥%-13x%" capscrews from the center of the crankshaft bearing cap. Place wooden block supports under the crankshaft and gear assembly to avoid possible damage by dropping when bearing cups are removed. Remove the three capscrews which hold the crankshaft bearing housing at each side of the pump case. Insert 2 %"-13 tap bolt about 4” long into the hole at the center of each housing and turn the screw as Suggested in illustration, to move the housing from the pump. Remove the self locking nuts, connecting rod caps, and bearing from each connecting rod assembly and mark as suggested in illustration. MARK ©=FMC Technologies Servicing the Drive End (Continued) Procedures CAUTION Be sure to match and mark each cap and connecting rod for matching when reassembling the pump. Failure to do so could cause damage to connecting rods. Work crankshaft through bearing opening in the case. Pull connecting rods and crosshead assemblies (A & B) from case taking caro to place parts so they will be reassembled in the same bore from which they were removed. Remove the two set screws (D) used to lock each crosshead pin in the crosshead assembly and remove crosshead pin. Press bushings out and replace with new bushings if necessary. Bring the bushings in position to 1.2505 in. plus 001 to 000. Using automotive type puller to remove the bearing cones from the crankshaft Inspect the eccentric shaft bearings tor (@) cleanliness (b) rust spots when fotated (c) visible wear or damage (4) slack between the inner and outer races of the bearing. NOTE: All damaged bearings or bearings that have been removed from the shaft must be replaced with new bearings. If one bearing is faulty, itis a good practice to replace both bearings even though no damage is visible on the other bearing.Inspect the eccentric shatt for damage, excessive scoring or pitting on the eccentric shaft indicates a need for replacement. Inspect the connecting rods for damage; excessive scoring or pitting on the connecting rods indicates a need for replacement. Inspect the crosshead assemblies and replace it any wear is visible. Clean all parts in a solvent and apply thin coat of oll (grade SAE 30) before installing. Thoroughly clean casing cap in solvent and blow dry. Press new bearings in place CAUTION Use extreme care when installing bearings. They can be easily damaged,shortening their life and efficiency. Reassembly the crosshead assemblies and connecting rods. Be sure to return both set screws to each hole to lock the pins in place with the inner screw seated in the indention on th outer face of the pin. Replace connecting rods in their original openings from which they were assembled. Be sure connecting rad oil Pockets are in the up position. Replace the pinion bearing cover. The pinion bearing cover has grooves inside as shown in the illustration. These Qrooves serve as an oil seal only when the cap is centered carefully around the shaft before final tightening of the. capscrews. Replace capscrews in the pinion cover. The pinion bearing cover has grooves Inside as shown bn Fig. 10. These ones seve as carefully arouna the shat before Final tigntening of tho cap screws F-12FM Crechnologies Servicing the Drive End (Continued) Replace connecting rod caps with original connecting rods. Torque nuts 10 65, Ibs. CAUTION Be sure to match each cap and connecting rod as they were originally assembled. Failure to do so could cause premature wear in connecting rods or shaft. Replace gaskets on crankshaft bearing housings. 40 | Replace the crankshaft bearing housings with their original shims and tighten capscrews. 41 | Proper endplay adjustment in the assembled crankshaft and bearings is required to avoid excessive bearing wear. The crankshaft should have between .002 tight and .003 free ‘endwise movement. Before checking endplay the connecting rods should be loosened to allow {ree movement to the crankshaft. 42 | Move the crankshaft fully to one end and place dial indicator against the face of the gear as shown in the illustration. 43 | Set the dial indicator at zero and move the crankshaft indicating its total ‘endwise movement. NOTE: The force required to move the crankshaft should be only enough to insure total endwise movement but not enough to spring the sides of the pump case, F-13If inplay is not between .002 tight and .003 free remove crankshaft bearing housings and adjust shim. Shim should be equally distributed between the two ends of the shaft. Replace the magnetic drain plugs in the side of the pump case. Torque connecting rod nuts to 65 ft. Ibs. Replace the capscrews, cover and gaskets from the power end of the pump. Refill the case with 4 gts. of clean high grade SAE 30 weight ol Turn the pump a few revolutions by hand to be sure that all parts are properly installed and adjusted betore returning the pump to its mounting, Replace fiuid end of the pump as described under Servicing the Gylinders. F-14FM Crechnologies Servicing the Bearings - A knocking sound around the bearing or excessive neat coming from the pump case adjacent to the bearing are indications Of faulty bearings. To replace or inspect bearings the crankshaft must be removed to allow access to the bearings. (Refer to Servicing the Drive End) Reading the Troubleshooting Chart The following chart is designed to nelp you easily define and correct problem areas. As you can see tho chart is divided into two columns. The first item is the Symptom, this is the signal that something Is wrong. Once you have noticed the symptom you must determine the Cause because ‘one symptom may be the signal for any one of various problems. The column titled Test and Result will be your aid for determining the Cause and Remedy. F-15Troubleshooting Chart ‘Symptom Discharge Pressure Too Low TosuResult ‘Cause/Remedy Connect a hose to the overflow port in the relief valve and start the pump: 4. Close all guns and/or nozzles and check overtiow. RESULT: No overflow, see item 1, then recheck Pressute. RESULT: Flow through overtlow hose, see item 2, then recheck pressure. 2. Open all of the discharge guns or nozzles. RESULT: No flow in the overtiow hose, see items 3 and 4; recheck pressure. RESULT: Flow through the overflow hose, see items 5 and 6, or 7; recheck pressure. 1. Restriction in suction line. Checked for clogged strainers, closed valves, ‘empty suction tank. 2. Incorrect relief valve adjustment. To increase the rolief pressure, tighten the nut on top of the valve by turning clockwise. | (Reter pg. D1.) | | Warning Do not exceed the rated pressure of the pump. 3. Incorrect nozzle size. Worn nozzles or nozzles with capacity in excess ‘of the pump capacity, will reduce the discharge pressure - replace where required. Refer nozzle manufacturer's literature 4. Pump speed too low. Change the sheave combination to obtain the desired speed. Caution Do not exceed the maximum rated speed. 5. Worn seat or stem in the relief valve. Replace parts as required. 6. Worn packing cup in the relief valve. Replace the packing if water is leaking through the openings in the relief valve body. 7. Foreign material lodged in the reliet valve. Relieve the spring tension and flush the interior of the valve to remove foreign material F-16