MODELS - Pentair Water Literature
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1. 13 C aller S TP RETE 13 Shim Adjustment of Tapered Roller Bearings 13 Installation of Crankshaft Oil Seal 13 Disassembly 532 2 x x 2 nsu us ein Rada ga 13 14 Connecting Rod Crosshead Extension Rod Crosshead Pin and Wiper Box Assembly Disassembly 14 eric 14 Installing Wrist Pin Bushings 14 Pinning the Crosshead 15 Order of Assembly 15 Precision Crankpin Crankthrow Bearings 15 Wiper Box Assembly 16 E e EE E E E E E 16 Poly Pak Seal 16 Mechanical Oil 16 Inserting the Plunger 16 Stuffing Box Packing and Plunger Assemblies 16 ua uu satmak 16 Spring Loaded Packing 17 J Style Stuffing Box amp Plunger Assembly Styles 838 and 858 17 18 Inserting the 1 18 PENTAIR MYERS APLEX SERIES Installing the Gland 18 Installing the Stuffing Box 18 Connecting the 18 PACKING eeraa onenei nE 182. 4 800 psi 6 000 psi 425 psi 1 100 psi Discharge Connection Size 2 NPTF Suction Connection Size gt PENTAIR 3 NPTF MYERS APLEX SERIES Average Liquid Velocity thru Seat with 2 1 2 Plungers amp Double Stem Valves At 550 Crankshaft rpm At 350 Crankshaft rpm Average Liquid Velocity 2 1 2 Plungers at 500 rpm Suction Manifold Discharge Manifold eneral Overall Dimensions Length Width Height 36 3 8 37 5 8 15 Approximate Weights With Aluminum Bronze Liquid End With Ductile Iron Liquid End With Forged Steel Liquid End 945 Ibs 932 Ibs 990 Ibs CROSS SECTION DIMENSIONAL DRAWINGS OIL LEVEL SIGHT GLASS 21 5 8 3 4 DIA HOLES imme 4 PLACES 5 sss CRANKSHAFT 9 3 8 L 20 14 H ge H 18 34 E CRANKSHAFT 11 34 1 9 16 ba 4 5 8 Cast Fluid End DIMENSIONAL DATA TABLE A2 DISCHARGE PORTS Ref No MA 60M MA 60H NOTE REQUIRED E DIRECTION OF ROTATION OIL LEVEL Lo m SIGHT GLASS 1 loll 9 MEZ M EX A5 PAO AP 0 A Discharge u 2 NPTF 2 NPTF 2 NPTF I Connection A Suction SUCTION PO
3. Using a socket socket extension and torque wrench tighten clean well oiled threads and nut faces Stud Threads 1 8UN at 1 8UN at 440 465 Ft Lb 400 465 Ft Lb CONNECTING THE PLUNGER Install the metal baffle plate on the extension rod and roll the pump slowly until the extension rod male threads just touch the mating plunger female threads Applying a pipe wrench to plunger knurled area thoroughly tighten the connection Do NOT use a cheater when connecting plunger to extension rod Serves no useful purpose and may damage the connection PACKING Packing life for aramid fiber packing may be improved in some applications by regular systematic lubrication An optional force feed lubricator assembly is often recommended especially for pumps on continuous duty This provides regular controlled supply of lubricant lowering friction and heat Additionally the regular application of the correct lubricant aids dissolving of salt and gyp tending to build up on the plungers in produced water applications For this service Rock Drill Lubricant is a popular and effective packing lubricant Plungers in ethane or other very cold liquid services may use brake fluid This fluid does not congeal into a solid which cannot enter the packing Consider the use of an air sealed cradle into which dry instrument air may be directed excluding the moisture which causes plunger icing especially in ve
4. A soft rubber mallet is recommended to avoid any damage to the plunger face or its threads Remember The fragile nature of packing rings and plunger surfaces deserves your respect and avoidance of careless damage to these key elements INSTALLING THE GLAND Considerable downward pressure on the gland is required to compress the spring to move the packing into location and to start the threads of the box Once the gland threads are started screw it down completely until it makes up tightly against the face of the box for spring loaded packing For Hi Lo J Style or Gland adjusted packing tighten the gland until it is seated firmly against the packing PENTAIR MYERS APLEX SERIES INSTALLING THE STUFFING B X JACK SCREW HOLES FOR BOX REMOVAL Aurora Pump Aplex Series stuffing boxes derive their alignment from the bores of the power frame and the faces of the fluid end So these surfaces MUST be cleaned of rust scale and dirt before assembly is begun Wash all contacting surfaces with clean solvent and dry with a CLEAN shop towel A nitrile rubber seal is used to seal between the face of the fluid end must be flat clean and smooth and the face of the box Replace if damaged stuffing boxes are retained by four large studs and nuts which extend through the power end serving to clamp the box and the power frame tightly against the fluid end face These four stud nuts must be EVENLY tightened
5. Automotive Type Ductile Iron Average Liquid Velocity thru Seat with 2 1 2 Plungers amp Plate Valves At 550 Crankshaft rpm At 350 Crankshaft rpm 8 7 fps 6 1 fps Average Crosshead Speed At 500 rpm 250 fpm Minimum Life Expectancy Main Bearings Lio iquid End Plunger Size Range Diameter 60 000 hr 3 Thru 1 1 4 Average Liquid Velocity thru Seat with 2 1 2 Plungers amp Double Stem Valves At 550 Crankshaft rpm At 350 Crankshaft rpm 8 3 fps 5 8 fps Maximum Continuous Working Pressure Nickel Aluminum Bronze and Ductile Iron Forged Steel 3 200 psi 4 000 psi Hydrostatic Test Discharge Nickel Aluminum Bronze and Ductile Iron Forged Steel Suction Nickel Aluminum Bronze and Ductile Forged Steel 4 800 psi 6 000 psi 425 psi 1 100 psi Average Liquid Velocity 2 1 2 Plungers at 500 rpm Suction Manifold Discharge Manifold Overall Dimensions Length Width Height 4 1 fps 10 4 fps 36 3 8 37 5 8 15 Discharge Connection Size 2 NPTF Suction Connection Size 3 NPTF Approximate Weights With Aluminum Bronze Liquid End With Ductile Iron Liquid End With Forged Steel Liquid End 945 Ibs 932 Ibs 990 Ibs MA 60H ENGINEERING DATA MA 60H ENGINEERING DATA Power End Model Triplex Pump MA 60H Maximum Input HP at Speed 60 at 550 rpm Rated Continuous Plunger Load 4 752 lbs Stroke 3
6. Consistent knock Packing failure excessive Wear of liquid end parts Liquid end cylinder failure Wear of power end parts excessive Possible Cause Water in power end crankcase Drain Refill with clean oil Worn or noisy gear Replace Worn or loose main bearing crank pin bearing wrist pin bushing plunger valve seat low oil level NOTE High speed power pumps are not quiet Checking is necessary only when the sound is erratic Improper installation Adjust or replace Add oil to proper level Install per instructions Improper or inadequate lubrication Lubricate per instructions Improper packing selection Change to correct packing Scored plungers Replace Worn or oversized stuffing box bushings Repair or replace Check bore and outside diameter of bushings frequently Many times plungers are replaced and bushings ignored Plunger misalignment Abrasive or corrosive action of liquid Realign Plungers must operate concentrically in stuffing box Check valves and seats frequently at start up to determine schedule for replacing etc Eliminate sand abrasive air entering pump Incorrect material Air entering suction system Poor lubrication Install correct materials Eliminate air NOTE Pitting often leads to hairline cracks which ends in cylinder failure Replace oil as recommended in instructions Keep oil clean and a
7. Maximum Rated Continuous Speed Normal Continuous Speed Range 500 rpm 150 to 450 rpm Minimum Speed 100 rpm Oil Capacity 9 U S Quarts Viscosity S S U at 210 F Power End Oiling System 70 to 84 Splash amp Scoop Power Frame One Piece Cast Iron Crosshead Full Cylindrical Cast Iron Crosshead Diameter x Length 4 3 4 x 5 Crankshaft Ductile Iron Crankshaft Diameters At Drive Extension At Tapered Roller Bearings At Crankpin Bearings Diameter x Length 2 500 2 499 2 5 8 3 1 2 x 3 Crosshead Wrist Pin Case Hardened and Ground AIS 8620 Wrist Pin Bushing SAE 660 Diameter x Width 1 1 2 x 2 1 4 Main Bearings Tapered Roller Timken Crankpin Bearings Precision Automotive Steel Backed Babbitt Lined Extension Pony Rod Diameter Material Connecting Rod Automotive Type 1 1 2 416 S S Ductile Iron Average Crosshead Speed At 500 rpm 250 fpm Minimum Life Expectancy Main Bearings Lio iquid End Plunger Size Range Diameter 60 000 hr 1 Thru 1 3 8 Maximum Continuous Working Pressure Forged Steel amp Forged Stainless Steel 5 000 psi Hydrostatic Test Discharge Forged Steel amp Forged Stainless Steel Suction Forged Steel amp Forged Stainless Steel 7 500 psi 425 psi Discharge Connection Size 1 1 2 NPTF Suction Connection Size Available Liquid End Mat
8. end face down and crankshaft end up Insert one bearing cup in the left frame cup bore and shoulder it against the bearing retainer with rubber mallet Pass the crankshaft through the right frame bore and against the installed cup until the bearing cone seats into the left bearing cup Insert a second bearing cup over the right hand crankshaft journal Install O ring on the crankshaft extension guard Tap the guard over the crankshaft extension if an auxiliary drive is not being used SHIM ADJUSTMENT OF TAPERED ROLLER BEARINGS To provide for crankshaft thermal expansion sufficient shims located beneath bearing retainer flange must be installed to provide 005 to 015 lateral end play when shaft is cold A feeler gauge and a 1 micrometer caliper are required Install a trail shim set on one side of the pump Tighten the flange bolts on this side only CAUTION Lubricate the frame bores and the O ring seals located in each carrier to prevent damage during entry Oil the bearings Omitting the shim set on the opposite side draw up the carrier evenly tightening its cap screws Rotate the crankshaft slowly by hand seating all rollers into running position 13 Measure the gap existing between the frame face and carrier flange The correct thickness of the shim set to be installed on this side equals the measure gap Plus about 010 No preload After installing above shim set a dial indicator may be used ag
9. 114238 271 Cap Screw x 2 3 8 Long Valve Cover 7202 0438 00B 1 x 4 1 8 Stuffing Box Stud 7507 2794 00A 1 8 Thrd Nut Fin Hex 127 100008 243 3 4 Hex Hd Pipe Plug S S 170 034002 250 Seal Valve Cover Nitrile Rubber 7202 0041 00A Seal Valve Cover Teflon Optional 7202 0041 01A Fluid End Assembly MA 60M SC 95 RO 86 Quantity Description Part Number Fluid End Steel Consult Factory Valve Cover 7202 0304 00B Stud Stuffing Box 7507 2794 00A 1 8 Thrd Nut Fin Hex 127 100008 243 3 4 Hex Hd Pipe Plug 170 034002 250 Valve Cover Gasket Nitrile Rubber 7202 0041 00A Seal Valve Cover Teflon Optional 7202 0041 01A Stud Power Frame to Liquid End 7202 0544 00A 1 1 4 7 UNC Heavy Hex Nut 133 114007 273 Fluid End Assembly a MAH A o pjk 1 2 Quantity Description Part Number Fluid End Consult Factory Valve Cover Plug 7203 0636 00A Stud Stuffing Box 7507 2794 00A 1 8 Thrd Nut Fin Hex 127 100008 243 3 4 Hex Hd Pipe Plug 170 034002 263 Valve Cover Seal Nitrile Rubber 7203 0637 00A Seal Valve Cover Teflon Optional 7203 0637 10A 1 1 4 Hex Head Cap Screw 100 114700 273 1 Hex Head Cap Screw 100 100234 273 Retainer Plate Valve Cover 7202 0637 00B 1 2 Screw Cap Hex Hd 100 012114 273 2 3 4 5 6 6 7 8
10. 5 11 Use the following table in adjusting V belt tension Belt Tension at Mid Span Cross Section New Belts Used Belts B 5 6165 3 1 4 5 Ibs 6 1 2 9 3 4 Ibs 3 7 1 2 Ibs 13 23 Ibs 9 3 4 13 Ibs 4 10 Ibs 17 30 Ibs Applying the above forces with a small spring scale adjust motor position to provide the following deflection at mid span Deflection inches 1 4 3 8 Approx Center Distance Span inches Belts must be matched in pitch length If one or two belts are slack when the others are correctly tensioned investigate for possible reasons Correct any misalignment or lack of matching so each belt will transmit its load share Sheaves must be balanced to prevent abnormal vibration Balancing weights must NOT be removed Type QD sheaves must be evenly tightened on their tapered hubs to avoid rim wobble and severe lateral vibration V belts that snap and jerk will produce abnormal vibration and loads on both pump and motor or engine Run the pump several minutes at full load with belt guard removed observing for uneven motion on the belt slack side especially When an old V belt drive becomes unserviceable replace ALL belts not just the broken or cracked belts Do not operate belts on sheaves having worn rusted greasy or broken grooves Shut off power to driver before servicing drive or pump WARNING Do not op
11. 60M SC 95 RO 86 7202 0059 00B Plunger Diameter Stuffing Box Seal Nitrile Rubber 3 7202 00 7202 0012 00A Stuffing Box Steel 4 7202 0453 00C Stuffing Box Alum Bronze 4 7202 0008 20C 7202 0181 00B Gland Alum Bronze 5 7202 0007 00B 7202 0014 00A 7202 0012 00A 7202 0012 00A 1207 0453 00C 1202 0453 00C 1202 0008 20C 1202 0181 00B 1202 0008 20C 1202 0007 00B 1202 0007 00B 1202 0014 00A 1202 0012 00A 1202 0454 00C 1202 0021 20C 1202 0180 00B 7202 0180 01B 7202 0014 00A 7202 0012 00A 1202 0454 00C 1202 0021 20C 1202 0180 00B 7202 0180 01B 7202 0014 00A 7202 0012 00A 1202 0454 00C 1202 0021 20C 1202 0180 00B 7202 0180 01B 7202 0014 00A 7202 0012 00A 1202 0454 00C 1202 0021 20C 1202 0180 00B 7202 0180 01B 7202 0014 00A 7202 0012 00A 7202 0623 00B 1202 0023 20B 1202 0179 00B 7202 0179 01B 7202 0014 00A 7202 0012 00A 7202 0623 00B 1202 0023 20B 1202 0179 00B 7202 0179 01B 7202 0014 00A 7202 00 7202 0012 00A 7202 0012 00A Stainless steel available Teflon available 7202 0012 99A 1202 0184 00C 84 00C 25 1202 0009 20C 1202 0178 00B 1202 0009 20C 1202 0178 00B 1202 0178 01B 1202 0178 01B Fluid End Assembly Quantity Description Part Number Fluid End Ductile Iron 7202 0183 10E Fluid End Nickel Aluminum Bronze 7202 0069 10E 1 1 4 NC Socket Head 105
12. Grades Approximate Weights With Aluminum Bronze Liquid End With Ductile Iron Liquid End With Forged Steel Liquid End 945 Ibs 932 Ibs 990 Ibs RO 86 ENGINEERING DATA RO 86 ENGINEERING DATA Power End Model Triplex Pump MA 60M Maximum Input HP at Speed 60 at 550 rpm Rated Continuous Plunger Load 4 752 lbs Stroke 3 Maximum Rated Continuous Speed Normal Continuous Speed Range 500 rpm 150 to 450 rpm Minimum Speed 100 rpm Oil Capacity 9 U S Quarts Viscosity S S U at 210 F Power End Oiling System 70 to 84 Splash amp Scoop Power Frame One Piece Cast Iron Crosshead Full Cylindrical Cast Iron Crosshead Diameter x Length 4 3 4 x 5 Crankshaft Ductile Iron Crankshaft Diameters At Drive Extension At Tapered Roller Bearings At Crankpin Bearings Diameter x Length 2 500 2 499 2 5 8 3 1 2 x 3 Crosshead Wrist Pin Case Hardened and Ground AIS 8620 Wrist Pin Bushing SAE 660 Diameter x Width 1 1 2 x 2 1 4 Main Bearings Tapered Roller Timken Crankpin Bearings Precision Automotive Steel Backed Babbitt Lined Extension Pony Rod Diameter Material Connecting Rod Automotive Type 1 1 2 416 S S Ductile Iron Liquid End Continued Available Liquid End Materials ASTM Nickel Aluminum Bronze Forged Steel Block Ductile Iron Stainless Steel B148 C
13. PENTAIR MYERS APLEX SERIES 26 THIS PAGE INTENTIONALLY LEFT BLANK STANDARD LIMITED WARRANTY CENTRIFUGAL amp RECIPROCATING PUMPS Pentair Myers warrants its products against defects in material and workmanship for a period of 12 months from the date of shipment from Pentair Myers or 18 months from the manufacturing date whichever occurs first provided that such products are used in compliance with the requirements of the Pentair Myers catalog and technical manuals During the warranty period and subject to the conditions set forth Pentair Myers at its discretion will repair or replace to the original user the parts that prove defective in materials and workmanship Pentair Myers reserves the right to change or Improve its products or any portions thereof without being obligated to provide such a change or improvement for prior sold and or shipped units Seals piston cups packing plungers liners and valves used for handling clear fresh nonaerated water at a temperature not exceeding 120 F are warranted for ninety days from date of shipment All other applications are subject to a thirty day warranty Accessories such as motors engines and auxiliary equipment are warranted by the respective manufacturer and are excluded in this standard warranty Under no circumstance will Pentair Myers be responsible for the cost of field labor travel expenses rented equipment removal reinstallation costs or freight expenses to and from the factor
14. SC 95 Maximum Input HP at Speed 60 at 550 rpm Liquid End Continued Plunger Type Rokide Stainless Steel Chromium Oxide Coated 416 S S Rated Continuous Plunger Load 4 752 Ibs Stroke 3 Maximum Rated Continuous Speed Normal Continuous Speed Range 550 rpm 150 to 450 rpm Stuffing Boxes Field Removable and Replaceable Aluminum Bronze Stainless Steel Hardened Carbon Steel B148 C955 17 4PH 1020 Minimum Speed 100 rpm Oil Capacity 9 U S Quarts Viscosity S S U at 210 F Power End Oiling System 70 to 84 Splash amp Scoop Packing Types Available Gland loaded Nonadjustable Spring loaded Cup Type Spring loaded Braided Teflon amp Kevlar Spring loaded Garlock Style 838 Style 120X Style 140 141 Style 8921K Power Frame One Piece Cast Iron Crosshead Full Cylindrical Cast Iron Seals Stuffing Boxes Valve Covers Cylinder Heads Studs Material ASTM Buna N A193 Grade B7 Cadmium Plated Crosshead Diameter x Length 4 3 4 x 5 Crankshaft Ductile Iron Crankshaft Diameters At Drive Extension At Tapered Roller Bearings At Crankpin Bearings Diameter x Length 2 500 2 499 2 5 8 3 1 2 x 3 Available Disc Valve Types Optional Standard Acetal Resin Optional Hardened and Lapped Double Stem Guided Delrin 17 4PH S S 17 4PH S S Crosshead Wrist Pin Case Hardened and G
15. SI 39 VH9SIQ TWAYON N3HM 3ATVA 431734 30 WWIYLSNMOG LINS3Y TIIM 1VH1 NOIII0N03 JOUNS IHL 304 30N3WW093 SI NOLIN3LLV YYINIILYYd SquvzvH TWILNALOd 3NWA 393VH9SIQ 9NIN3d0 TI04 39003 01 33080 NI SNOILI0N02 13Sdf NV 1 9NILV33d0 304 SONLWY 3U 1SS3ud 1V3S SNINAGO TIN4 HLIM 3ATVA Y93H9 9NIMS ALON 339 3ivno30v 3AVH LSNIN SIN3N0dN02 N31SAS TIY OT nS 6 310N 339 3193NN09 140 SI H3HIV3M 0109 2 3313231 TIVAS V J101 SI dd N3HM CNY 3ATVA 4417494 IYNSSIYd SY AYINI JUNSSIYd 398VHOSIC J0 1SNIV9V N3ISAS NOILONS 10410844 01 6 T 310N 339 FINI NOILINS 40 3NITH31N39 38 LSNW ONIdid JYVHOSIG ANY NOLLORS 8 3015 Lyd 4390038 21313223 CASN 41 YINIdANYG ONY NOLLOVINOO NOISNVdX3 WAWININ NOLLWSINd 393VH2SIQ TWWUGHL 9Nldld 30 S193443 3ZIWININ 3ZIS NOILOINNO9 NOLLONS IMYA 2018 NV OL 3N0I1IS0d 38 CINOHS YlYd 1NIOf 1SV31 1v LSN 1 39nv9 IUNSSIUd TANIMS 1 NOISNVdX3 ISOH 318IX314 8019V4 NOLIVHTT39OV 1 ALON 339 V NOLLVMSIA NV NIVHIS 9NIdid OL NO SQN3d3Q 3NI1 40 1715 14 a SLINA 9 4 3141110 31 IMYA 39018 NV 39nv9 JUNSSIYd 3T8VMIS3Q 3l 3A WA 1004 ann 30 3SOH TIS 3QfrT9NI ALIDOT3A A31N3 AINON 31VMVd3S INN LIINI NOLLOAS N 04 04091540 71138 NOILINS A 9NIO9100 WOXI T 3
16. gt PENTAIR MYERS APLEX SERIES MUDELS MA 60M MA 60h 10 06 TRIPLEX PUMPS INSTALLATION AND SERVICE MANUAL NOTE To the installer Please make sure you provide this manual to the owner of the equipment or to the responsible party who maintains the system Part AP 03 103 2014 Pentair Ltd 01 14 14 Engineering Data WAG OW CER 3 MAS OI MMC 4 S0 05 u 5 T 6 Dimensional Data 7 Installation Operation Lubrication Maintenance and Storage Instructions 8 SERRE 8 SOE 8 Pump Location and Piping Design 8 SUCTION PIPING essen oes 8 9 Acceleration Head 9 Discharge PIPING 9 10 Bypass PIPINE Sakis eve ste irn ane 10 25 E 10 V Belt Drive 10 12 Suggested Piping System for Plunger Pumps 11 Direction of 12 Automatic Safety Shutdowns 12 Crankshaft Assembly 12 eric m 12 Tapered Roller Bearings 12 13 Cup Installation aaa asun tone 13 Installing Crankshaft
17. not be directed back to the pump suction system WARNING mproper use of this equipment could result in loss of life CALIFORNIA PROPOSITION 65 WARNING WARNING This product and related accessories contain chemicals known to the State of California to cause cancer birth defects or other reproductive harm STORAGE Pumps are shipped dry from the factory If a pump has been in storage in a humid environment for more than 6 months the crankcase cover should be removed and carefully examined for rust or water collected in the power end Flush out any evidence of rust or damage that exists using a light clean oil Pumps to be placed in extended storage should be cleaned repaired as needed and completely filled to the top with clean oil to prevent rusting Rotate pump monthly 4 1 2 revolutions Plug all openings to prevent air entry and oil leakage Fluid ends must be completely drained of water and suction and discharge ports blanked off Store pump in a clean dry location PUMP LOCATION AND PIPING DESIGN Locate pump and driver in a clean well drained ventilated and brightly illuminated area with adequate PENTAIR MYERS APLEX SERIES working spaces around the pump to provide ample access to fluid end power end and associated drive elements Do not expect good maintenance to result if the pump is positioned on muddy terrain or in a dirty cramped dimly lighted area The supply tank s should be large t
18. to insert it into the packing Other plunger types are available upon request 19 DUAL STEM GUIDED AND DISC VALVE SYSTEMS GENERAL Aurora Pump Aplex Series has developed a unique setting puller system permitting quick easy and safe methods of installing and removing tapered seat valves The system allows servicing without distortion of the seat with minimum effort and NO damage to fluid end tapers or seat Tapered seats notoriously drive solidly down into mating deck tapers so firmly that extraction heretofore has always posed severe problems Old style valves may be pulled only with the greatest effort using J puller heads prone to failure CO dry ice and other improvisations DISC VALVE CONSTRUCTION TYPICAL DISC VALVE LOCK NUT SPRING RETAINER SPRING VALVE DISC VALVE STEM PULLING THREADS VALVE SEAT TYPICAL ABRASION RESISTANT VALVE GUIDE CAGE VALVE SPRING O RING POLYURETHANE PULLING THREADS 0 RING NITRILE RUBBER DUAL STEM VALVE VALVE SEAT The Aurora Pump Aplex Series valve is a precision made subassembly using threads cut into the rim of seat for use with Aurora Pump Aplex Series setting pulling tool These threads do NOT deteriorate as proved by field experience By locating these on the rim setting pulling forces are now applied only to the rim of the seat never to the webs or spokes or to the center section Distortion of the seat is eliminated Acc
19. while affording easy field installation Before beginning the assembly all parts must be scrupulously cleaned removing all oil dirt rust and foreign matter which prevent proper fitting or which might tend to score the rubbing surfaces Clean and examine the power frame bores for scoring and abnormal wear especially wear of the lower crosshead guide way Hone smooth if rough Measure the bores of the frame using inside micrometers to determine abnormal frame wear if any Crosshead 0 D 4 744 4 743 New Frame Bores 4 749 4 750 Frame bores that have become worn more than 015 must be sleeved with a cast iron liner to re establish correct geometry and alignment Contact Aurora Pump Aplex Series concerning the repair of badly worn frame bores Smooth any rough corners and edges on the crosshead skirts using fine emery cloth Examine and clean the female tapered threads and wrist pin holes PENTAIR MYERS APLEX SERIES INSTALLING WRIST PIN BUSHINGS The wrist pin bushing is precision machined bearing bronze which is press fitted into the eye of the connecting rod CONNECTING ROD EYE BORE WRIST PIN BUSHING 0 D Bushing 0 D 1 759 1 758 Connecting Rod Eye 1 755 1 757 Carefully align the bushing with its hole and after applying oil to bushing O D use a hydraulic press to force it home When a bronze bushing is pressed into place the I D bore of the bushing is reduced somewhat owing to the ext
20. 071 20K 7202 0319 00C 100 038034 273 7502 0125 00A 170 012001 237 7602 3000 00A 157 014200 235 170 014002 405 7602 3001 00A 7202 0010 00C 7602 0130 09B 7501 2713 00A 7602 5310 72 Quanti Power Frame Crankcase Cover 3 8 NC Hex Head Cap Screw x 3 4 Long Gasket Crankcase Cover 1 2 Pipe Plug Square Head Oil Level Sight Gauge 1 4 Pipe Nipple Std Wt 2 Long 1 4 Pipe Plug Square Head Breather Crankcase 3 4 NPTM Connecting Rod subassembly which includes Wrist Pin Bushing Connecting Rod Bolts AR Safety Wire PENTAIR MYERS APLEX SERIES 24 Crankshaft Assembly 3 Stroke Right Hand and Left Hand Drive Right Hand Shown MA 60M MA 60H SC 65 RO 86 MA 60M MA 60H SC 65 RO 86 Quanti Description Crankshaft Assembly includes items 1 amp 2 Crankshaft Drive Key Part Number PE109K Quantit Description O Ring Nitrile Rubber Part Number 001500191 7202 0001 10B 1 2 NC Hex Head Cap Screw 1 1 4 Long 100 012114 273 146 058600 236 Crankshaft Kit includes items 1 2 3 amp 4 Bearing Cone Tapered Roller Bearing Cup 109 1 2 Lockwasher Spring Medium Shim Set 154 012087 244 7502 0238 00A 203 983600 999 Oil Seal 145 256312 999 202 023600 999 Bearing Carrier Drive Side 7202 0060 00B Bearing Carrier Blind Qty 3 per pump ea MA
21. 10N 33S N SNIIOONI 31V Td N S Tudv8 3983W8 S A131314W09 x 1N04dnS ONY X310A NMOHS LON SNOILYONNO4 NV YANG SNOLL23NNO2 39WWHOSIQ NG NOI190S 1900 7 HLM dd YI NNTA TINOZINOH CHIVI SI FUNSSIUd 13S N3HM ATINA SN3d0 9SI0 1S808 431138 9NIN3d0 TI4 G 310N 33S 9NIQV01 OL dNNd NI lv 1343 YNYL QLN340 INYA SSVdA8 30H2 3WNWI31 03VH 31033N Alddns 1s LILON 338 0 NOISNYdX3 0 3S0H 3184 nmm qm 2 ILON 339 NAWININ IMYA INIOd THAT INON WNWINIW YNYL 01NI INON 1344 INIT SSYdAS ONY INIT 0334 9 9 4 1 HO 9NILNV1S ATIVOLINWOLOV ITNI NOLLONS 9NIN3d0 TI0J BON WEIL AT Lucis SSVdA8 1 AYNCOML V 0941530 41 G 9 310N 339 UTR pe 04 0101 TIILVIOA 304 SV ABVSS393N SI 9NIDHVH2 V JI NMOHS INI0d LV dd 9NI98VH9 31V901 Y ONIOIAYAS 9 4 GINDIT 3A08V YO 30 1N01 N 1N3NWdI 103 33H10 Y0 ONIdld 31V90110N 00 LINDUID SSVdA8 NI AINON TIY ONY S3ATVA 340H9 ANY 331133 Alda ATINA TIIM 1NIOd MOTOS SSVdA8 3d01S Z Q3T134X3 SI ANY 4 4 JHL S3H9V33 A TLdINOSd N31SAS NOLLONS NI ANY OS JATA 131N NOILONS 30 3NITH3LN3O NVHL U3H9IH ATLHOTTS 38 OL LIINI NOLLORIS 4 4 30 3NITH31N3O T 53100 SdNNd YFINN Id HOA W3 SAS 9NIdId 315399
22. 19 19 Dual Stem Guided and Disc Valve Systems 19 General a a 19 Disc Valve Construction uuu u Ta 19 Setting the Valve 20 Installing Disc Spring Disc Valves and Stem 20 Valve Spring Options 20 Valve Disc Options 20 21 Pulling the Valve 21 Salvage of Worn Seats 21 Other PUMP Brands 21 Trouble Location and Remedy 22 24 Parts Lisu ll l l ilis iisas SSS 24 26 u u u oce cce de usa aa aku recta aaae iaa 28 MA 60M ENGINEERING DATA MA 60M ENGINEERING DATA Power End Model Triplex Pump MA 60M Maximum Input HP at Speed 60 at 550 rpm Rated Continuous Plunger Load 4 752 Ibs Stroke 3 Liquid End Continued Available Liquid End Materials ASTM Nickel Aluminum Bronze Forged Steel Block Ductile Iron Stainless Steel B148 C955 A105 A536 80 55 06 Various Grades Maximum Rated Continuous Speed Normal Continuous Speed Range 500 rpm 150 to 450 rpm Plunger Type Rokide Stainless Steel Chromium Oxide Coated 416 S S Minimum Speed 100 rpm Oil Capacity 9 U S Quarts Viscosity S S U at 210 F Power End Oiling System 70 to
23. 84 Splash amp Scoop Power Frame One Piece Cast Iron Crosshead Full Cylindrical Cast Iron Crosshead Diameter x Length 4 3 4 x 5 Stuffing Boxes Field Removable and Replaceable Aluminum Bronze Stainless Steel Hardened Carbon Steel Packing Types Available Gland loaded Nonadjustable Spring loaded Cup Type Spring loaded Braided Teflon amp Kevlar Spring loaded Garlock B148 C955 17 4PH 1020 Style 838 Style 120X Style 140 141 Style 8921K Crankshaft Ductile Iron Seals Stuffing Boxes Valve Covers Cylinder Heads Buna N Crankshaft Diameters At Drive Extension At Tapered Roller Bearings At Crankpin Bearings Diameter x Length 2 500 2 499 2 5 8 3 1 2 x 3 Studs Material ASTM A193 Grade B7 Cadmium Plated Crosshead Wrist Pin Case Hardened and Ground AISI 8620 Wrist Pin Bushing SAE 660 Diameter x Width 1 1 2 x 2 1 4 Available Valve Types Standard Acetal Resin Optional Hardened and Lapped Double Stem Guided Delrin 17 4PH S S 17 4PH S S Main Bearings Tapered Roller Timken Valve Spring Material Inconel Crankpin Bearings Precision Automotive Steel Backed Babbitt Lined Extension Pony Rod Diameter Material 1 1 2 416 S S Valve Seat Liquid Passage Areas Plate Disc Valves Delrin or S S Double Stem Guided Valve 2 3 sq in 2 4 sq in Connecting Rod
24. 955 A105 A536 80 55 06 Various Grades Plunger Type Rokide Stainless Steel Chromium Oxide Coated Stuffing Boxes Field Removable and Replaceable Aluminum Bronze Stainless Steel Hardened Carbon Steel 416 S S B148 C955 17 4PH 1020 Packing Types Available Gland loaded Nonadjustable Spring loaded Cup Type Spring loaded Braided Teflon amp Kevlar Spring loaded Garlock Style 838 Style 120X Style 140 141 Style 8921K Seals Stuffing Boxes Valve Covers Cylinder Heads Studs Material ASTM Buna N A193 Grade B7 Cadmium Plated Available Valve Types Standard Acetal Resin Optional Hardened and Lapped Double Stem Guided Delrin 17 4PH S S 17 4PH S S Valve Spring Material Inconel Valve Seat Liquid Passage Areas Plate Disc Valves Delrin or S S Double Stem Guided Valve Average Liquid Velocity thru Seat with 2 1 2 Plungers amp Plate Valves At 550 Crankshaft rpm At 350 Crankshaft rpm 2 3 sq in 2 4 sq in Average Crosshead Speed At 500 rpm 250 fpm Minimum Life Expectancy Main Bearings Lio iquid End Plunger Size Range Diameter 60 000 hr 3 Thru 1 1 4 Maximum Continuous Working Pressure Nickel Aluminum Bronze and Ductile Iron Forged Steel Hydrostatic Test Discharge Nickel Aluminum Bronze and Ductile Iron Forged Steel Suction Nickel Aluminum Bronze and Ductile Forged Steel 3 200 psi 4 000 psi
25. IS WARRANTY FOR IMPROPER INSTALLATION PENTAIR MYERS RECOMMENDS INSTALLATION BY PROFESSIONALS Some states do not permit some or all of the above warranty limitations or the exclusion or limitation of incidental or consequential damages and therefore such limitations may not apply to you No warranties or representations at any time made by any representatives of Pentair Myers shall vary or expand the provision hereof gt PENTAIR MYERS MYERS APLEX SERIES 1101 MYERS PARKWAY ASHLAND OHIO USA 44805 419 289 1144 WWW FEMYERS COM Warranty Rev 12 13
26. RTS Connection 3 NPTF 3 NPTF NPTF 36 15 16 36 172 Block Fluid End B2 28 14 28 14 Bl B3 9 1 4 8 14 B2 PUMP OIL LEVEL Bt 23 6 310 DISCHARGE CONNECTIONS SICIL GLASS 8 Discharge vanne depends om om onnections i a Suction 3 ANSI 9008 onnections aasan es Cl 37 5 8 C ME ME C2 28 3 8 M C3 7 5 16 Jl C4 3 5 8 SUCTION CONNECTIONS Block Fluid End C Discharge gt Gon gr Cl Connections OIL LEVEL C Suction 2 C2 DISCHARGE CONNECTION Pump SIGHT GLASS Connections 3 LUFRE 01 31 9716 18 9 16 18 9 16 18 9716 18 5 8 INSTALLATION OPERATION LUBRICATION MAINTENANCE AND STORAGE INSTRUCTIONS SAFETY Electrical power or engine must be shut off completely before attempting service on the pump or its drive Air surrounding the unit to be free of toxic flammable or explosive gases Tools needed should be planned for in advance see valve seat pulling instructions and should be clean and of adequate size A torque wrench will be required to tighten connecting rod cap screws A properly sized and set relief valve installed in the pump discharge system ahead of any block valves is necessary to protect personnel and to avoid dangerous overpressure The relief valve set pressure should be not more than 25 above the design operating pressure and should discharge to tank or to the atmosphere toward the ground and must
27. ainst the end of the shaft to confirm the shim selection Bump the shaft in one direction and zero the dial indicator Bump the shaft the opposite way If shimming is correct the shaft will move laterally from 005 to 015 About equal shim set totals are required under each carrier flange The recommended tightening torque for bearing retainer 1 2 13UNC cap screws is 59 to 72 ft Ib INSTALLATION OF CRANKSHAFT OIL SEAL Insert oil seal over the end of crankshaft and position it into the oil seal bore in the bearing retainer Using a rubber mallet tap it into the bore until the face of the seal is flush with the bearing retainer DISASSEMBLY After removing the connecting rod cap and cap bolts note identifying marks on each cap so each may be later correctly reassembled onto its own rod remove a bearing carrier from the frame Two jack out tapped holes are provided in the flange of the carrier for this purpose Support the shaft during removal to avoid damage The crankshaft may now be extracted once all connecting rods are moved clear Examine the crankpin surfaces for wear or corrosive pitting The correct diameters of these journals are Crankpin Diameter 3 4975 3 4965 If worn more than 010 undersize crankshaft should be replaced or an attempt to salvage it may be made at a shop well equipped to grind the crankpins which must be fully round chromeplated and finish ground to t
28. ate vapor Suction lift too great Decrease lift Raise tank level Broken valve springs Replace Stuck foot valve Clean Pump valve stuck open Remove debris beneath valve Clogged suction strainer Clean or remove Relief bypass pressure valves leaking Piping too small and or too long Repair Increase size and decrease length Use booster pump Use suction and or discharge pulsation dampeners Worn valves or seats Replace or reface Piping inadequately supported Gas in liquid Improve support at proper locations Submerge return supply or makeup lines in suction supply tank If operating under a suction lift check joints for air leaks Pump valve stuck open Remove debris beneath valve Pump not filling Increase suction pressure One or more cylinders not pumping Prime all cylinders Allow pump to operate a low pressure through bypass valve to eliminate vapor Excessive pump speed Reduce Check drive ratio Worn valves or seats Replace or reface Broken valve spring Replace Loose plunger Tighten Loose or worn bearings Adjust or replace Worn crossheads or guides Replace Loose crosshead pin Loose connecting rod cap bolts Adjust or replace Pump running backward MYERS APLEX SERIES 22 Correct rotation TROUBLE LOCATION AND REMEDY Trouble
29. conomical than the use of charge pumps or expensive suction stabilizers NOTE Charge pumps should be sized to 150 of rated pump volume Charge pumps need to be centrifugals not a positive displacement pump A charging pump is usually not a good substitute for a short direct oversize suction line nor is it a substitute for the computation of available NPSH acceleration head friction head vapor pressure and submergence effects duly considered Required NPSHR of Aurora Pump Aplex Series pumps depends on speed choice of plunger size and valve spring type Consult Aurora Pump Aplex Series Engineering for help with your particular application A full discussion of suction system losses is given in the Standards of the Hydraulic Institute 14th Edition A common design mistake is the connecting of two or more reciprocating pumps to a COMMON suction header This is a profoundly complicated suction system largely not amenable to mathematical analysis and is frequently the cause of severe pump pounding vibration and early valve failures Each pump should be fed by its own separate individual piping system free from the effects of other pump cyclical demands for liquid DISCHARGE PIPING A properly designed discharge piping system usually prevents the need of a pulsation dampener The most common mistakes made in the design of the discharge piping system are 1 Pumping directly into a tee or header A standing wav
30. e either audible or subaudible then often occurs If flow must enter a header use a 45 branch lateral or equivalent to avoid a reflecting surface from which sound can reflect 2 Pumping into short radius 90 elbows Instead use two 45 elbows spaced 10 or more pipe diameters apart 3 Pumping into a right angle choke valve 4 Pumping into too small piping line size Piping should be sized to keep fluid velocity below 15 feet per second max 5 Pumping through an orifice plate small venturi or reduced port regular opening valve 6 Pumping through a quick closing valve which can cause hydraulic shock water hammer A good discharge piping system includes 1 A properly sized correctly set relief valve Discharge from relief valve returned to tank not to pump suction 2 A full opening discharge gate or ball valve Avoid restricting plug valves globe valves and angle valves 3 A pressure gauge with gauge dampener or snubber Consider a liquid filled gauge Scale range to be double the normal pump operating pressure Locate the relief valve and pressure gauge ahead of any block valve and so that the pressure in the pump is always reflected at the relief valve The relieving capacity of the relief valve must exceed the capacity of the pump to avoid excessive pressure while relieving Use a full size relief line To minimize vibration whether hydraulic or mechanical discharge lines should be
31. e pump All boxes are retained by four 4 studs and nuts and are centered in the frame bore ensuring correct alignment The plungers may also be removed separately without box removal to facilitate repacking With this option the necessary space required to remove plunger it is first necessary to remove the extension rod SPRING LOADED PACKING Compression Packing SPACERS GLANDRING 7 Z RAK N Sp PPN PACKING SPRING EL s lt lt NN LESS GLANDRING Chevron Packing SPRING GUIDE Note that the gland is screwed tightly onto the box and contacts its face The spring is providing all of the initial compression and adjustment No adjustment is provided by the gland Since the force exerted by the spring is contingent on the space provided for it the correct lengths of all rings are essential for good tensioning Spring A stiff Inconel spring which closely fits the bore of the stuffing box is used in this assembly This spring is compressed in a vise to the operating length required plus 0 25 and tied with waxed nylon spot tie cord The cord is looped over the ends of the spring through the coils and tied to maintain the length mentioned above Each spring is assembled into the stuffing box Note that the spring does not contact the plunger Spring Guide Ring Plungers are heavy and the importance of a well fitted guide ring that carries this weight is ofte
32. ed into MA 60M pump before the crankshaft assembly TAPERED ROLLER BEARINGS Shaft and frame tolerances provide a tight shrink fit on the shaft and in the carrier The best way to install the cone assembly consists of the inner race cage and rollers on the shaft is to heat the cone assembly in an electric oven for 30 minutes at 300 to 400 F No more DO NOT heat bearings with an acetylene torch This ruins the bearings Using clean insulated gloves remove the hot cone assembly from the oven promptly dropping it on to the shaft The cone assembly MUST contact the seat thrust face not be cocked and the large end of the rollers MUST be down Do not hammer on the bearing The soft steel cage is easily distorted ruining its function as a roller separator and guide against skewing If the cone does not contact its thrust face properly it must be pressed into place using a specially machined sleeve which does not touch the soft steel cage A hydraulic press is recommended if this difficulty arises CUP INSTALLATION Tapered roller bearing cup outer races is a press fit in the bearing carrier using a hydraulic press Cup must be pressed into a clean carrier until the race solidly abuts its shoulder must not be cocked The tool or plate used for this must contact only the outer end face not on the taper INSTALLING CRANKSHAFT GENERAL Stand the power frame casting on the floor or on a bench with the fluid
33. ellent smoothness and the flatness needed for good sealing and smooth running Metal valve discs may sometimes be salvaged by grinding or lapping if not deeply cut or cracked Delrin discs are relatively inexpensive and salvage is seldom worthwhile Replace the stem if severely worn Inconel valve springs rarely require replacement OTHER PUMP BRANDS Aurora Pump Aplex Series Industries can provide its unique patented valve to fit nearly all brands and models of multiplex pumps An Aurora Pump Aplex Series seat setting puller tool is available too Trouble Pump fails to deliver required capacity Suction and or discharge piping vibrates or pounds Pump vibrates or pounds gt PENTAIR Possible Cause Speed incorrect Belts slipping TROUBLE LOCATION AND REMEDY Change drive ratio or tighten belts if loose Correct motor speed Air leaking into pump Seal with compounds Liquid cylinder valves seats or plungers worn Reface or lap valves and seats replace packing or plungers Insufficient NPSHA Pump not filling Increase suction pressure Prime pump Makeup in suction tank less than displacement of pump Increase makeup flow Reduce pump speed Vortex in supply tank Increased liquid level in supply tank Install vortex breaker One or more cylinders not pumping Prime all cylinders Allow pump to operate at low pressure through bypass valve to elimin
34. ent of press fit Therefore a clean new wrist pin should be inserted into the bushing bore to establish that running clearance has been obtained Oil Clearance 0004 0016 Replacement bushings are furnished prebored by Aurora Pump Aplex Series which usually eliminates the need to ream the installed bushing bore However due to slight variations in finishes and tolerances it sometimes happens that more than predicted contraction of the I D occurs This occurrence results in a slight interference which may be eliminated by lightly honing the bore of the bronze NOT by reducing the pin size An automotive engine repair shop usually is equipped with power honing machines capable of smoothly finishing the bushing bore Bore of bushing must be round and free of taper PINNING THE CROSSHEAD A pressfit is employed between the crosshead pin and crosshead to secure the pin against any motion CONNECTING A hydraulic press is RODWITH BUSHING employed to force the pin through lt lt the bosses of the crosshead WRISTPIN CROSSHEAD A mishap during insertion can occur causing the ruin of the pin or the crosshead if during application of pressure V TYPE BLOCKS a Pin is not aligned absolutely square with the crosshead b Crosshead is not supported on v blocks so it can roll while under load c Connecting rod is not fully supported so pin cannot enter the bushi
35. erate without appropriate guards in place DIRECTION OF ROTATION Before placing pump in operation check that crankshaft rotation agrees with the arrows cast on top of the power frame by briefly jogging the electric motor PENTAIR MYERS APLEX SERIES Crankshaft rotation must be clockwise as viewed from the right side of pump If pump is gear driven remember that the pinion shaft turns opposite the crankshaft if using a single reduction geared drive or in the same direction as the crankshaft when using a planetary gear AUTOMATIC SAFETY SHUTDOWNS Carefully check all electric shutdown devices present such as crankcase oil level discharge pressure vibration lubricator oil level motor thermostat etc CRANKSHAFT ASSEMBLY GENERAL Aurora Pump Aplex Series crankshaft suspension uses two single row tapered bearings which are shim adjusted to provide the correct running clearance Thorough cleaning of all components prior to assembly is essential Power frame shaft bearings and retainer MUST be scrupulously scrubbed with clean solvent such as kerosene before starting Remove any oil dirt rust and foreign matter which might prevent the correct fit up Crankshaft journals are critical Remove all burrs rust spots and nicks paying special attention to the ground areas on which bearings and oil seals operate Connecting rods and crossheads must be previously install
36. erials ASTM Forged Steel Block Stainless Steel gt PENTAIR 2 NPTF MYERS APLEX SERIES Liquid End Continued Plunger Type Rokide Stainless Steel Chromium Oxide Coated 416 S S Stuffing Boxes Field Removable and Replaceable Stainless Steel Hardened Carbon Steel 17 4PH 1020 Packing Types Available Spring loaded Cup Type Spring loaded Braided Teflon amp Kevlar Style 120X Style 140 Seals Stuffing Boxes Valve Covers Cylinder Heads Buna N or Teflon Studs Material ASTM Available Valve Types Optional Hardened and Lapped Abrasion Resistant A193 Grade B7 Cadmium Plated 17 4PH S S 17 4PH S S Valve Spring Material Inconel Valve Seat Liquid Passage Areas Plate Disc Valves Delrin or S S Double Stem Guided Valve 2 4 sq in 2 3 sq in Average Liquid Velocity thru Seat with 1 3 8 Plungers amp Plate Valves At 550 Crankshaft rpm At 350 Crankshaft rpm Average Liquid Velocity thru Seat with 1 3 8 Plungers amp Double Stem Valves At 550 Crankshaft rpm At 350 Crankshaft rpm 2 5 fps 1 7 fps Average Liquid Velocity 1 3 8 Plungers at 500 rpm Suction Manifold Discharge Manifold eneral Overall Dimensions Length Width Height 36 1 2 30 3 4 16 5 8 Approximate Weights With Block Liquid End 990 Ibs SG 95 ENGINEERING DATA SG 95 ENGINEERING DATA Power End Model Triplex Pump
37. ess to these seat threads is provided by the removal of the valve cage on D S G valves or the spring retainer on Disc valves which is screwed onto the seat An anti seizing lubricant applied to all threads is good insurance against future difficulty SETTING THE VALVE SEAT INSERT 1 2 BAR TO UNSCREW HEAD di FROM SEAT PULLER STEM DISCHARGE VALVE DECK PULLER HEAD SUCTION VALVE Effective pressure sealing between tapered male seat and tapered female fluid end deck is possible ONLY if the tapers are absolutely clean and dry just prior to installation Thoroughly clean surfaces using a clean solvent Dry with a CLEAN shop towel Examine the cleaned fluid end deck tapers using a flashlight and remove all deposits of gyp salt or other incrustation Using emery cloth lightly rub out any minor imperfections found in the deck taper The puller stem and puller head are provided with tapered locking threads Screw them together using two pipe wrenches applied to the knurled areas provided Then screw the valve seat onto the puller head by hand until it shoulders against the puller shoulder Do not tighten Lower the seat and puller assembly into the fluid end squarely setting the seat into the deck Then pound the top of the stem with a 6 pound hammer until a solid metalic sound is heard usually 2 or 3 blows Unscrew the head and stem from the seat using a 1 2 bar or screwdriver into the ho
38. he above sizes Aurora Pump Aplex Series does not perform this function Crankshaft tapered roller bearings should be carefully examined for pitting scoring or corrosion and replaced as required The cone and roller assembly is most easily removed by first cutting away the cage using an acetylene cutting torch Then heat the cone inner race with the shaft held vertically so cone will drop off due to its own weight Avoid excessive heat on the crankshaft which tends to distort its geometry Cups outer races of tapered roller bearings may be extracted from bearing carrier using a conventional bearing puller tool of the automotive type widely available Do not attempt to use heat on a bearing carrier as this will result in severe distortion out of round Replace the bearing carrier if broken or out of round CONNECTING ROD CROSSHEAD EXTENSION ROD CROSSHEAD PIN AND WIPER BOX ASSEMBLY DISASSEMBLY GENERAL Aurora Pump Aplex Series connecting rod assemblies employ precision automotive type steel backed babbitt lined crankpin bearing halves which require no shims for clearance adjustment This pump employs full circle piston type crossheads and hardened stainless steel extension rods which are field replaceable Extension rods are provided with wrenching flats to permit tightening of the tapered thread into the crosshead establishing accurate alignment
39. iltering the liquid as it enters the supply tank rather than as it leaves it The use of an eccentric reducer with the flat side up located at the pump suction connection is recommended The suction line should slightly rise from tank to pump and loops in which air may collect must be avoided The absolute pressure in a suction line may be less than atmospheric pressure and air may be sucked into the line unless all flanges and connections are airtight and watertight If you can see water leaking out of a suction line when the pump is still that may mean air is being sucked in when the pump is running Suction piping should be buried beneath the frost line or insulated to avoid freezing in the winter If the suction line has a block valve at the supply tank a suitable relief valve is suggested to relieve the suction piping from any possible dangerous overpressure from the discharge piping system Suction piping is often large heavy especially when filled with liquid and tends to vibrate Proper solid supports are recommended A suction hose located near the pump will isolate these effects protecting the pump from the forces and moments that piping weight creates New suction piping systems should be flushed free of pipe scale welding slag and dirt before starting the pump Hydrostatic testing to detect air leaks is advisable Proper choice of suction hose construction is essential to avoid collapse of the hose liner I
40. kept short direct well supported and solidly anchored Avoid dead ends and abrupt direction changes BYPASS PIPING Some designers ignore this important aspect of proper design of pump piping systems A reciprocating pump especially after maintenance of the valves or plungers STARTS WITH ONE OR MORE FLUID CHAMBERS FULL OF AIR Pumps operating on propane butane or other volatile liquids START WITH VAPOR IN THE FLUID CHAMBER S Positive displacement pumps do not automatically purge themselves of air and gas after shutdown For example a quintuplex plunger pump will after servicing expel the air in four of the five pump chambers Thus the pressure from four of the active cylinders will keep shut the discharge valve of the inactive or air bound cylinder Then the air or gas in this cylinder will be compressed and expanded by its reciprocating plunger and never leave the chamber Similar effects occur in duplex and triplex pumps To overcome these difficulties adequate provision for expelling the gas in the air bound cylinders must be present Common practice is to totally relieve the pump of all discharge pressure during the start up after servicing Consider the operational advantage of a full sized bypass line return to tank which substantially removes discharge pressure from all cylinders during the start This requires a block valve on the discharge side and a full opening bypass va
41. le provided at the top end of the stem INSTALLING DISC SPRING DISC VALVES AND STEM Aurora Pump Aplex Series offers discs of Delrin acetal resin of 17 4PH S S hardened and ground and of titanium alloy PENTAIR MYERS APLEX SERIES 20 Position the disc and Inconel spring on the seat aligning the hole in the disc with the stem threads in the seat center The stem spring retainer and locknut are shipped from Aurora Pump Aplex Series already assembled and tightened with a torque wrench with Loctite sealant added to the top stem threads only Stem Threads Tightening Torque 1 2 13UNC 65 75 ft Ib Use an anti seizing lubricant in these threads This is very necessary when seats and stems of Type 316 stainless steel are selected optional to prevent galling CLEANLINESS of threads and other contacting surfaces is of paramount importance in the assembly of all valve elements VALVE SPRING OPTIONS All Aurora Pump Aplex Series valve springs are made of Inconel material precisely designed and fabricated Unless otherwise specified the standard spring is furnished It provides excellent results in the great majority of applications Pumps employed in marginally available NPSH conditions may require a softer spring to reduce the required NPSH For these special conditions Aurora Pump Aplex Series can supply light valve springs which exert lower pressure on the valve disc The use of light valve sp
42. lve on the other side For economy the bypass to tank can be combined with the relief valve discharge line This line must be full sized well supported and sloped downward to avoid freezing in cold weather A frozen relief valve line provides NO protection to either the pump or operating personnel The ability of a reciprocating pump to be self priming depends on the ratio of the swept displaced volume in the cylinder to the unswept clearance volume at the end of the stroke This depends on the design of the fluid end and on the plunger size selected Choice of the largest size plunger for a particular fluid end improves this compression ratio and so PENTAIR MYERS APLEX SERIES leads to self priming or easy priming Choice of the minimum size plunger sometimes leads to difficulties especially with pumps that require frequent servicing or which handle volatile liquids or which contain substantial amounts of dissolved air or gas An automatic bypass and purging system for these applications may be merited LUBRICATION Aurora Pump Aplex Series pumps use S A E 40 wt nondetergent oil in the crankcase This oil requires only a nonfoaming additive and should possess good water separation antiemulsion characteristics Such oils are often labeled industrial or turbine quality lubricants If these oils are not available a good quality gear oil or EP oil may be substituted See lubrication guideline
43. n overlooked Discard any guide ring that becomes worn or scored as it will then not serve its purpose It should fit snugly in the box Apply oil generously to this ring Spring Loaded Packing Three 3 rings of chevron or compression packing are installed next For compression packing install them with the skive intersections 180 apart to discourage leaking Gland Ring This ring also fits the plunger and helps support the plunger weight Discard it if bore is worn rough or out of round Lightly oil the ring before insertion The gland ring fits all packing 17 J STYLE STUFFING BOX amp PLUNGER ASSEMBLY STYLES 838 amp 858 GLAND PACKING SET THROAT BUSHING BAFFLE LANTERN RING The above depicts Styles 838 and 858 packing correctly installed with all packing lips facing TOWARD the fluid pressure Note that two 2 units of Styles 838 and 858 packing are positioned ahead of the lantern ring and one 1 unit is positioned behind it Thus lubricant entering the lantern ring is forced toward the pressure Throat Bushing Plungers are heavy and the importance of a well fitted throat bushing that carries this weight is often over looked Discard any throat bushing that becomes worn or scored as it will not then serve its purpose It should fit snugly in the bottom of the box Apply oil generously to this ring Styles 838 and 858 Packing Styles 838 and 858 are a NON adjustable t
44. ng without damage to it This will damage the bushing d Failure to oil pin O D and crosshead bores to prevent galling Use clean motor oil After installing the pin carefully check the crosshead O D to see if it is out of round If so a smart blow with a rubber mallet will restore the crosshead O D into its original roundness ORDER OF ASSEMBLY The connecting rod crosshead assembly is installed BEFORE the crankshaft is installed because the wiper box wall bore is smaller than the crosshead O D This is most easily done by setting the power frame vertically and dropping each crosshead assembly into its frame bore FRAME BORE CRANKSHAFT NOT INSTALLED CONNECTING ROD SHANK CROSS HEAD amp PIN WIPER BOX WALL FLOOR OR BENCH TOP 15 NOTE The connecting rod must clear the frame bore circle in order to introduce the crankshaft in these models PRECISION CRANKPIN CRANKTHROW BEARINGS Aurora Pump Aplex Series pump crankpin bearings require no shimming to establish correct running clearance Precise machining of the connecting rod caps and crankpin journals is necessary to achieve this convenience New Connecting Rod Bore 3 748 3 750 Crankpins that are worn out of round tapered or badly scored should either be discarded or perhaps salvaged by grinding undersize hard chrome plated and finish ground to above diameter Aurora Pump Aplex Series does not offer this service Connec
45. nstall a dry type compound gauge in the suction line near the pumps which should fluctuate evenly If violently pulsating this gauge indicates that the pump is not fully primed or that one or more valves are inoperative ACCELERATION HEAD A characteristic of all reciprocating pumps is the imperative need to consider the effects of acceleration head which is a SYSTEM related phenomenon Acceleration head may be considered to be the loss of available hydraulic head energy in the piping system occurring because the demand by the pump cylinders for liquid is not smooth and even Because the pump s demand for liquid is cyclical the velocity of the liquid in the entire suction system is not truly constant but varies in response to the combined demand of the reciprocating plungers Thus liquid in the suction system is compelled to be accelerated and decelerated several times during each crankshaft revolution depending on the number of plungers Called acceleration head this loss of available hydraulic head is proportional to a The speed RPM of the crankshaft b c d The number of pumping chambers triplex etc The average liquid velocity in the piping The length of the suction piping e The compressibility of the liquid Thus for a given pump acceleration head effects may be reduced by the use of the shortest possible suction line sized to reduce liquid velocity to a very low speed This is often more e
46. o allow dissolved air and other gases to escape from the liquid and allow suspended solids to settle out before entering pump A system employing dams and settling chambers is desirable CAUTION All pumps should be installed level For mobile applications the maximum angle of intermittent operation pumps SC pumps should be no more than 5 degrees in any one direction Pumps are not designed to withstand piping weight vibration and the effects of thermal piping expansion contraction Piping loads may be considerable and the weight of all valving dampeners filters and associated forces moments and couples must be completely isolated Use flexible hoses and rigid piping supports to isolate the pump and its driver from these effects SUCTION PIPING No part of the piping system deserves more careful planning than the suction piping system Suction piping must be SHORT DIRECT and OVERSIZE Use one pipe size larger than the pump suction connection The shorter it is the better 1 to 3 feet per second suction velocity is acceptable Reference the following table to size a direct suction line from a tank to a pump Suction Piping 23 3 _ 4 MA 60H MA 60M SC 95 R0 86 Use no elbows tees or restricted port valves in this line Do not install orifice plates or positive displacement type fluid meters in the suction line which act as flow restrictors Avoid the use of suction filters if possible Consider f
47. rings may be limited by the choice of plunger size and or limited by the chosen speed of the pump Light valve springs may be impractical for pump models fitted with their maximum plunger size or which operate near top speed rating as disc bouncing and erratic seating may occur VALVE DISC OPTIONS Aurora Pump Aplex Series acetal resin discs made of DuPont Delrin are machined flat and smooth to produce perfect sealing on the lapped flat face of the seat Used successfully in thousands of applications these discs are light slightly flexible under load and seal well even at high pump speeds providing smooth pump action Acetal resins are very resistant to most corrodents but are not usually suitable where fluid temperatures are above 120 degrees Nor do they afford long life at extreme pressures Pressure limitations depend on valve size But continuous valve operation at pressures above 2 500 psi usually indicates the need of metal valve discs For higher temperatures or pressures Aurora Pump Aplex Series offers lapped flat hardened Type 17 4PH stainless discs or titanium alloy discs These metal discs are less tolerant of any fine grit in the liquid and are noisier than the acetal resin disc Contact Aurora for more information PULLING THE VALVE SEAT First drain the fluid end entirely For D S G valves use the cage wrench to unscrew the cage from the seat For Disc Valves unscrew the stem from the seat Remo
48. round AISI 8620 Valve Spring Material Valve Seat Liquid Passage Areas Plate Disc Valves Delrin or S S Double Stem Guided Valve Inconel Wrist Pin Bushing SAE 660 Diameter x Width 1 1 2 x 2 1 4 Main Bearings Tapered Roller Timken Crankpin Bearings Precision Automotive Steel Backed Babbitt Lined Average Liquid Velocity thru Seat with 2 1 2 Plungers amp Plate Valves At 400 Crankshaft rpm At 550 Crankshaft rpm Extension Pony Rod Diameter Material Connecting Rod Automotive Type 1 1 2 416 S S Ductile Iron Average Crosshead Speed At 450 rpm 225 fpm Minimum Life Expectancy Main Bearings Lio iquid End Plunger Size Range Diameter 18 000 hr 2 1 2 Thru 2 Average Liquid Velocity 2 1 2 Plungers at 400 rpm Suction Manifold Discharge Manifold Overall Dimensions Length Width Height eneral 36 3 8 30 5 8 15 Maximum Continuous Working Pressure Discharge 3 200 psi Hydrostatic Test Discharge Side Suction Side 4 800 psi 425 psi Discharge Pipe Thread Size 2 NPT Suction Pipe Thread Size 3 NPT Maximum Working Pressure Suction Manifold 275 psi Discharge Connection Size 2 NPTF Suction Connection Size 3 NPTF Available Liquid End Materials ASTM Nickel Aluminum Bronze Forged Steel Block Ductile Iron Stainless Steel B148 C955 A105 A536 80 55 06 Various
49. ry humid conditions Packing lubricant for pumps on light hydrocarbons hot water lean oil naphtha or gasoline often requires experimentation A good start is to use steam cylinder oil Castor oil is sometimes successful as a packing lubrication for liquid propane and butane services at ambient temperature In pumps placed in arctic service a special low pour point oil is indicated Packing lubrication is not permitted on some services such as amine food stuffs etc and other packing styles and materials may be required PLUNGERS Aurora Pump Aplex Series offers its own unique product the Aurora Pump Aplex Series Rokide plunger This premier quality plunger consists of a chromium oxide deposition on a solid stainless steel body Ordinary handling will not damage this fine product Avoid striking the coated surface black during installation Apply light forces only on the ends of the plunger Do not hammer or pry All threads on Aurora Pump Aplex Series plungers must be CLEAN and oiled before assembly Stainless steel although very corrosion resistant has a tendency to gall and seize To avoid this an anti seizing lubricant is well worth its use Apply oil to the threads and the rubbing surface Aurora Pump Aplex Series can supply solid ceramic plungers on order This plunger is very fragile vulnerable to thermal and mechanical shock and must be handled with the greatest care Use only a rubber mallet
50. s In temperate climates oil viscosity selected should fall between 70 and 84 seconds Saybolt viscosimeter at 210 In arctic service low pour point oils are needed After the first 500 hours of operation in a new pump drain the oil Refill with clean fresh oil Thereafter change the oil every 1 500 hours or sooner if it becomes contaminated with water or dirt Fill to the center of the sight gauge Recheck after starting adding oil to center of gauge while running The oil capacity is 9 U S quarts V BELT DRIVE A properly designed well aligned V belt will provide years of reliable economical service if properly tensioned and kept dry free of oil and ventilated Alignment is critical for long life If the shaft axes are not truly parallel or if the sheave grooves are not positioned in good alignment some belts will carry most of the load resulting in their disproportionate load share and may actually twist or turn over in the groove Use a straight edge across the rim of the sheaves to detect and correct for misalignment After about one week of operation new V belts will have stretched somewhat The motor must be moved on its slide base to re establish proper belt tensioning Insufficient tension results in slippage burning squealing especially during starting and shortened belt life Overtightening imposes excessive loads on pump and motor bearings and can cause early shaft fatigue failure 39018
51. s sometimes referred to as the diaphragm stuffing box or stripper housing assembly serve two important functions retention of crankcase oil in the power end and exclusion of dirt and water Aurora Pump Aplex Series has developed a unique sealing set which operates on a hardened and ground stainless steel extension rod often called pony rod and a steel baffle disc affording protection against leaking plunger packing The seals require no adjustment only correct and careful assembly POLY PAK SEAL This seal keeps oil from leaking out of the power frame Developed by the Parker Seal Group this patented rod seal employs a soft nitrile rubber O ring to energize a special hard polyurethane Molythane shell by forcing the inner lip against the rod and the outer lip against the housing bore as shown The Poly Pak seal is inserted into its counter bore with its lips directed toward the oil in the crankcase Will NOT work if installed backward WIPER BOX OUTER MECHANICAL SEAL BAFFLE PLATE POLYPAK ROD SEAL lt EXTENSION ROD TO CRANKSHAFT x MECHANICAL OIL SEAL PLUNGER The oil seal is to keep contamination out of the power frame With the box positioned in a hydraulic press install the backup seal against the Poly Pak seal with the lips of both seals facing downward WIPER BOX DT 7 gt A SUPPORT The mechanical seal contains a garter spring Check to
52. see that this spring is still properly located and in its position The mechanical seal has a metal case which serves to force the Poly Pak seal into its cavity energizing its lips Apply oil lightly to the bore of the box before pressing each seal into its counterbore PENTAIR MYERS APLEX SERIES INSERTING THE PLUNGER WRENCHING EXTENSION FLATS ROD TAPERED BOK THREADS Insert the extension rod through the wiper seals with the tapered thread and entering FIRST Care should be used in moving the extension rod through the seals with wrenching flats entering first Do not force The sharp corners on the wrenching flats may damage the seal lips Resulting in oil leakage With extension rod inserted through the wiper box seals thread the tapered threads must be clean into the tapered crosshead female threads Firmly tighten apply torque to the wrenching flats only Never damage the extension rod ground surfaces Then fasten the wiper box to the power frame by tightening the cap screws Oil leakage between frame face and wiper box is prevented by use of a gasket beneath the box flange STUFFING BOX PACKING AND PLUNGER ASSEMBLIES GENERAL Aurora Pump Aplex Series pumps all feature field removable and replaceable stuffing boxes with plungers separable from the extension rods If desired the boxes plungers and packing units may be installed or removed as a unit assembly permitting service outside th
53. t correct temperature Be sure oil is reaching all bearings Overloading Modify pump or system to eliminate overload Liquid in power end 23 Drain power end Eliminate cause or source of liquid entering power end Relubricate TROUBLE LOCATION AND REMEDY Excessive heat in power end Possible Cause Pump operating backward Correct rotation Above 180 Insufficient oil in power end Fill to proper level Excessive oil in power end Drain to proper level Incorrect oil viscosity Overloading Fill with correct oil Reduce load Tight main bearings Correct clearance Drive misaligned Realign Belts too tight Reduce tension Discharge valve of a cylinder s stuck open Fix valve s Insufficient cooling Provide adequate cooling for oil or reduce ambient temperature Pump speed too low Increase speed Power Frame Assembly Connecting Rod Crosshead amp Wiper Box Assembly 2 Z S lt PS MA 60M MA 60H SC 95 RO 86 Description MA 60M MA 60H SC 95 RO 86 Description Crankpin Bearing Pair Wrist Pin Crosshead Extension Rod Wiper Box Hex Head Cap Screw 3 8 x 1 Long Poly Pak Ring Oil Seal Gasket Wiper Box Part Number 7202 0190 00K 7202 0005 00A 7202 0056 00C 7202 0164 10B 7202 0017 50B 100 038100 273 145 112214 999 145 112212 999 7502 0600 00A Part Number Quantit 7202 0
54. ting rod cap bore must be perfectly round and within above sizes and free of taper Discard if elliptical or tapered as the result of abnormal heating Each cap and rod is match marked for correct identification Take care that each cap is reinstalled properly with its companion rod Bearing halves are identical and are prevented from rotating by tongues which fit into slots in the cap Check that all oil holes are clean and fully open GRIT is the greatest enemy of bearings however precisely manufactured Hence all surfaces must be perfectly clean and lightly oiled prior to assembly Remove any burrs or sharp corners which prevent the perfect fitting of these precision bearings Using a torque wrench tighten cap bolts as follows Thread Size 5 8 18UNC Tightening Torque 125 135 Ft Lb Specified torque applied to clean well oiled threads and bearing faces will create tensile stresses in the cap bolts from 90 000 to 110 000 psi approx and will provide correct initial tension Aurora Pump Aplex Series pumps use high strength cap bolts suitable for these initial loadings maintained by hardened spring lockwashers After all rods and caps are secured slowly turn the crankshaft to be sure no bearings is in a bind Using a flashlight examine the location of each connecting rod eye end within its crosshead Rods must not touch any crosshead boss or skirt WIPER BOX ASSEMBLY GENERAL Extension rod wiper boxe
55. ve the cage spring and valve from the fluid end Attach the Aurora Pump Aplex Series puller head to the puller stem tighten their tapered threads with a pipe wrench applied to the knurled areas of the puller stem and head Lower the stem and head into the fluid end and engage the threads of the head onto the seat threads Using a 1 2 bar or screwdriver rotate the head clockwise and thread it fully onto the seat But do NOT tighten Slide the bridge over the stem Clean and oil the stem threads Oil the face of the wing nut Thread wing nut down onto the stem seating it on the bridge top firmly Extract the seat from the pump by striking the wing nut with a heavy hammer A hydraulic ram may also be used Stand clear of the pump when applying heavy tonnage as the entire assembly will jump violently upward when the pulling energy is suddenly released The Aurora Pump Aplex Series puller setting tool and gauge tool are custom designed and built for each specific Aurora Pump Aplex Series pump model The same puller head is used on both suction and discharge seats The bridge is made to fit each model and its proper use will not damage the valve cover gasket machined counterbore on the top of the fluid end 21 SALVAGE OF WORN SEATS Rough valve seat faces may often be renewed by lapping or grinding if not deeply fluid cut Perfect flatness is required A surface grind followed by lapping on a lapping plate provides exc
56. y or an authorized Pentair Myers service facility This limited warranty will not apply a to defects or malfunctions resulting from failure to properly install operate or maintain the unit in accordance with the printed instructions provided b to failures resulting from abuse accident or negligence c to normal maintenance services and parts used in connection with such service d to units that are not installed in accordance with applicable local codes ordinances and good trade practices e if the unit is moved from its original installation location f if unit is used for purposes other than for what it is designed and manufactured g to any unit that has been repaired or altered by anyone other than Pentair Myers or an authorized Pentair Myers service provider h to any unit that has been repaired using non factory specified OEM parts Warranty Exclusions PENTAIR MYERS MAKES NO EXPRESS OR IMPLIED WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF PENTAIR MYERS SPECIFICALLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR ANY PARTICULAR PURPOSE Liability Limitation IN NO EVENT SHALL PENTAIR MYERS BE LIABLE OR RESPONSIBLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES RESULTING FROM OR RELATED IN ANY MANNER TO ANY PENTAIR MYERS PRODUCT OR PARTS THEREOF PERSONAL INJURY AND OR PROPERTY DAMAGE MAY RESULT FROM IMPROPER INSTALLATION PENTAIR MYERS DISCLAIMS ALL LIABILITY INCLUDING LIABILITY UNDER TH
57. ype packing which depends solely on hydraulic pressure to energize the sealing lips Gland tightening forces do NOT energize the lips Tightening and hydraulic end thrust loads are transmitted entirely through the center support portions of each ring The flattened portions of the rings are large enough to withstand overtightening Do NOT attempt to adjust this type packing It should be kept thoroughly tightened at all times Running it loose will ultimately ruin the bore of the box Running it loose will NOT usually cause it to drip at all but it can ruin the box in time Lightly oil each ring and the box bore and then lightly tap in each ring separately with the rings facing correctly This is most easily done before installing the plunger Lantern rings are provided with O D and I D reliefs and two or more oil holes to allow lubricant to reach the plunger After the last unit of Styles 838 and 858 packing is in place generously oil the lips of all seal rings to ease plunger entry SEALRING ADAPTER BOTTOM ADAPTER HARD PHENOLIC HARD PHENOLIC PRESSURE L ONE UNIT INSERTING THE PLUNGER TAP HERE USING RUBBER MALLET OILED PLUNGER BENCH TOP Apply oil liberally to plunger O D and lightly tap it through the packing When introducing the plunger through the MA 60M stuffing boxes also apply oil liberally to the O D of each extension rod to allow easy passage through the wiper box seals
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