Home

the American AW1118D Piston Pump service manual

Contents

1. 12 Months Crankcase Oil Drain and refill with new oil Clean magnetic drain plugs Sen eat Connecting Rod Bolts Inspect Check the connecting rod bolts with a torque wrench to insure they are within specification This should be done in conjunction with the oil change AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 26 of 64 American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Lubrication Recommended Lubricants Few factors can influence the life of a pump more than the power end lubricating oil Careful selection of the right type of oil for each particular application will help ensure optimal perform ance and pump life IMPORTANT Lubricant temperatures should not exceed 170 F 77 C for continuous duty or 180 F 82 C for intermittent duty applications Crankcase temperatures that exceed these limits will cause the lubricant to prematurely break down The result will be poor lubrication and the possible failure of power end components Table 5 Recommended Lubricants Oil Lubricant Synthetic Lubricant Ambient SSU Manufacturer ISO Manufacturer Temperature Viscosity Viscosity Brand Name Viscosity Brand Name 550 cSt 40 C cSt 40 C General 0 F to 100 F 30 100 Texaco Meropa 100 90 0 40 Shell Rotella T Service 18 C to 38 C Shell Omala 100 15 0 100 synthetic SAE 5W 40 Shell Rotella T SAE 30 Exxon XD 3 30 wt ZONA MODINE Ort Mobil Trans HD 30 13 9100
2. AW1118 13 8 AW1122 20 6 AW1118 522 AW1122 78 AW1118 19 7 AW1122 29 5 AW1118 74 6 AW1122 112 AW1118 25 AW1122 37 4 AW1118 94 6 AW1122 142 AW1118 29 6 AW1122 442 AW1118 112 AW1122 167 AW1118 35 5 AW1122 53 AW1118 134 4 AW1122 201 Horsepower is based on 85 or 90 efficiency Actual applica tion horsepower requirements can be calculated using this equation BHP GPM PSI 1714 0 85 or 0 90 Pump capaci ties listed are based on 10096 volumetric efficiency 350 rpm gals min 350 rpm liters min 500 rpm gals min 500 rpm liters min 635 rpm gals min 635 rpm liters min 750 rpm gals min 750 rpm liters min 900 rpm gals min 900 rpm liters min This document contains American Mfg Company proprietary and confidential information It is loaned for limited purposes only and remains the property of American Mfg Company It may not be reproduced in whole or part or disclosed to third parties without the prior written consent of American Mfg Com pany The document is to be returned to American Mfg Com pany upon request and in all events upon completion of the use for which it was used d A ANAL m CN pg RvAC TIE PERRY MANAGEMENT JOH NSON REGISTRARS Specifications are for both the AW1118 and AW1122 unless otherwise separately indicated All specifications are subject to change without notice ANI Page 11 of 64 American Mfg Company Chapter 3 Installation a
3. Family Operations an d Maintenance Manual Revision 2 AMI Page 51 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Figure 7 AW1122BCD Fluid End Components 62 50 59 9 50 ay 42 aw JOO A A 45 ERAY eus N Z GF 7 ZZ S TT ANE 4 P P A UPPER UA r rm ae ee d 1 gaa elis T Ld 31 WASSER E YV A N WW IS 48 SS es Kk X P Ws IN amp D G0 8 89 GO 0O00 S7 i B NS re f A JN SS MY 8 AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 52 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts LES Le m AW1122 Component Item and Part Numbers 1 PwerFame PPrmosesre 1 30 SuewSefTapng Prve teran 2 2 Torente PPM 1 ot Pate specion PPRMCSESOSGI 3 Pmonsmt PPro Psio 1 22 PrePusPowerEni PPRUCHISTMS 2 4 T connecing Rod Assy PPro S266814 3 33 Filer Coporvent PPRUCAREM 1 5 RwBewnp PPro Psioes 3 3M Sum PPRCHOGNO 20 6 Wn Penoas 3 35 Patek f Perv nero 1 7 Geseaiiesenby PPFWCtass 3 3I Fuin Chamber PPRICIGBATT 1 amp SesHde PPro 3 eA DscYnheAesemby PPRCIZIMM 6 9 ose PsonRod PPro nrmeo o 388
4. Pump Family Operations and Maintenance Manual Revision 2 ANMI Page 44 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 36 37 38 39 40 4 42 43 44 IF it is damaged remove the crankshaft oil seal Item 19 using a screwdriver or simi lar object and discard the old seal Thoroughly clean all parts with solvent and apply a thin coat of oil before reassembly The tapered roller bearing cups Item 24 may be heated to aid in assembly onto the shaft Always take proper safety precautions use heat resistant tools and wear gloves when handling hot parts There are a number of recommended methods for heating bearings Electric ovens or electrically heated oil baths may be used but not without proper thermostatic control To replace the tapered roller bearings on the crankshaft heat the cones to a maximum of 300 F 149 C Slide them down the shaft until they are fully seated against the shoulder The hot cup may pull away from the shoulder hold it in position until it cools and shrinks enough to grab the shaft Use a 001 thick feeler gauge to ensure that the cone is fully seated against the shoulder after the parts have cooled Use a press to seat the new cones Item 23 into the bearing housings Never use new bearing cups with old bearing cones Always use matched bearing cone sets from one manufacturer Reassemble the crosshead assemblies and connecting rod
5. Symbols DANGER indicates an imminently hazardous situation which if A DANGER not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or may result in damage to the machine AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 6 of 64 A American Mfg Co m pa ny Chapter 1 Safety Quality Mud Pumps and Parts Safety When Using the Pump EN TNI A WARNING Operate the pump only if this operating manual has been read completely and is well un derstood Check the pump for any damage Immediately inform the responsible superior about trouble or damage of the pump Do not begin or continue production when problems are encoun tered Ensure that no unauthorized persons are located near the moving parts of the pump Wear the necessary ear protection and safety clothing Check all safety and guard devices protecting the operating from the pump and from other moving machinery Check any fluid protection covers shields or other protective devices around the pump par ticularly when pumping hot or hazardous liquids A properly sized and configured pressure safety device pressure relief valve rupture disc etc must be installed before the pump is operated Ensure that no valves are p
6. any fluid protection covers shields or other protective devices around the pump particularly when pumping hot or hazardous liquids AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 19 of 64 A Quality Mud Pumps and Parts American Mfg Compa ny Chapter 4 Operation How to Start the Pump The following checklist is a general guide for starting a pump in a typical installation every in stallation is different and each will have its own requirements to ensure safe and successful op eration It is the operator s responsibility to determine the correct start up procedure for each installa tion Pump Starting Procedure l Make sure that the drain plug s on the bottom of the pump crankcase have been in stalled and are tight If the pump is equipped with an oil level sight glass make sure it has been properly in stalled Check the oil level to ensure that the pump is properly filled with non detergent motor oil gear lube or a synthetic oil as described in Table 5 page 27 and thot the oil has not been contaminated with any other fluid or particles NOTE American Mfg Company pumps are shipped with no oil in the power frame and must be filled to the proper level with the proper grade of oil prior to start up 3 9 IF they are accessible check the piston rods to make sure that they are free from abra sive particles or debris Check to see that the pressure relief valve and all relat
7. disc directly downstream of the pump This will help to prevent damage or injuries resulting from over pressure or deadhead conditions The relief valve discharge line must be as large as the pipe outlet of the relief valve and never install valves in the relief valve discharge line or between the pump and re lief valve American Mfg Company recommends that the discharge from the relief valve be returned to the tank or drain not back into the pump suction line For start up purposes install a start up bypass line and valve to allow flow to bypass the re lief valve This allows the pump to start in an unloaded condition no discharge pressure Figure 2 Discharge Line Gauges and Valves PRESSURE RELIEF PRESSURE GAUGE VALVE PPFMC 3546492 PPAM A000380000 DISCHARGE SURGE CHAMBER FOR 1 1 4 NPT PPAM A000350000 kgs 1 1 4 NPT INTAKE SURGE CHAMBER FOR 2 NPT J ONNO mn PPAM A000355000 9 i i 2 NPT i T INTAKE LINE AW11 Pump Family Operations and Maintenance Manual Revision 2 ANVI Page 15 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Storage Instructions Proper storage of your American Mfg Company pump will ensure that it is ready for use when needed Follow the guidelines below that fit the requirements of your application e American Mfg Company pumps come from the factory w
8. the belt manufacturer Verify that the sheaves are in line with and par allel to each other with a straight edge A DANGER If you are driving the pump with a V belt never operate the pump without the belt guard securely installed A DANGER If your pump is direct coupled or spline driven never operate the pump without a shaft guard securely installed Ensure that the shafts are centered and parallel when the driver is mounted to the pump Follow the coupling manufacturer instructions for installation procedures and tolerances AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 12 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Suction Piping Recommendations Poorly designed or implemented suction piping is the root of many pump problems Here are some recommendations to follow in designing or construction the piping to the pump The suction line from the fluid source to the pump as short and direct as possible The pipe size should at least be equal to or one size larger than the pump inlet Unavoidable long piping runs low suction heads or indirect pipe routing may require even greater over sizing of the suction line tor proper operation of the pump Avoid as best as practical the use of elbows nipples unions or other fittings Make sure that all joints and connections are air tight All piping should be supported independently of the pump do not make
9. the pump inlet one of the supports Properly supporting the piping this way reduces vibrations and stress on the pump Use rigid piping non collapsible hose or a combination of both as circumstances re quire To help isolate mechanical and hydraulic vibrations American Mfg Company rec ommends the use of flexible pipe couplings or hose connections between the pump and any rigid piping It is difficult to diagnose many pump problems without the aid of a suction pressure gauge For this reason American Mtg Company recommends that a suction pressure gauge always be installed in the suction line directly before it enters the pump Use a suction and discharge pulsation dampener to reduce the effects of acceleration head this will help when suction conditions are not optimal In some cases it may be neces sary to install a booster pump in the suction line of the pump to obtain sufficient pressure for the pump to operate successfully The suction line must be designed so that there are no high spots in the line where air pock ets can collect Air pockets make the pump difficult to prime and often cause rough and or erratic operation Air leaks reduce the capacity of the pump and can result in cavitation rough operation and or loss of prime drain valve or plug should be installed at the low point of the suction line to allow for draining before freezing conditions or for maintenance Always ensure that the calculated system Net Positive
10. to drive motor Adjust or replace relief valve Service Repair or replace check valves Check for damaged parts replace packing Increase speed check belts for slipping power to drive motor Adjust or replace relief valve Service Service Service repair or replace fluid cylinder Prime all Reroute bypass or relief fluid to tank Increase pipe diameter and or shorten run Provide more Net Positive Suction Head Service Increase inlet depth or use baffles to break up vortex Service Service clean deburr reseat or repair valve Service repair or replace fluid cylinder Correct suction line installation ANI Page 22 of 64 American Mfg Compa ny Chapter 5 Troubleshooting Quality Mud Pumps and Parts Rough operation knocking Valve spring broken or weak valve damaged Service valves replace springs as needed vibration repair or reseat valves Loose plunger s piston s or rod s Low oil power end Service Tighten all loose components l Fill to proper level Too much connecting rod bearing clearance piep Too much main bearing clearance Check cap torque and or replace bearings Worn wrist pin or bearings Adjust end play Service replace worn components Pump is running backwards 2 p Loose sheaves bushings in V belt drive Correct drive rotation Gear teeth cracked or missing Inspect and tighten belt drive components Insufficient NPSHA Excessive a
11. valve cover hex nuts to the recommend values listed on page 30 AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 39 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Servicing the Power End Replacing Piston Rod Oil Seals A WARNING Disconnect the pump from the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at the pump If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause elec trical shock or injury from moving pump parts or components under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Review all of the safety warnings listed in under Safety when Working on the A Pump on page 8 For item numbers see AW1122 Drawings starting on page 49 Table 9 AW11 Component ltem and Part Numbers page 53 AW1118 Drawings starting on page 54 Table 10 AW1118D Component Item and Part Numbers page 58 or Table 11 AW1118B Component ltem and Part Numbers page 59 14 The piston rod oil seals Item 9 retain oil in the power end and prevent contamina tion from entering the power end by way of the piston r
12. 09 08 2013 Pump AW 11 Family Operation And Maintenance Manual Factory Sales Office P O Box 640 736 19th Avenue NE A American St Joseph Minnesota 56374 Mig Company 888 299 3412 Toll Free Quality Mud Pumps and Parts 320 363 7273 Phone 320 363 7274 Fax info american manufacturing com www american manufacturing com pagi i Registered T JOHNSON 7k 0266 REGISTRARS ISO 9001 2008 RAN ms QUALI E m SIS ACCREDITED A American Mfg Company Contents Quality Mud Pumps and Parts Copyright 2013 American Mfg Company This manual covers the American Mfg Company Model AW1 1 triplex piston pump family of pumps Model Pinion Shaft Shaft End AW1122D Left hand 1 1 2 diameter 3 8 square keyway shaft end AW1122D R Right hand 1 1 2 diameter 3 8 square keyway shaft end AW1122D SP Left hand 1 1 2 diameter 14 tooth splined shaft end AW1122D R SP Right hand 1 1 2 diameter 14 tooth splined shaft end AW1118D Left hand 1 1 2 diameter 3 8 square keyway shaft end AW1118D R Right hand 1 1 2 diameter 3 8 square keyway shaft end AW1122BCD Left hand 1 1 2 diameter 3 8 square keyway shaft end AW1122BCD R Right hand 1 1 2 diameter 3 8 square keyway shaft end AW1122BCD SP Left hand 1 1 2 diameter 14 tooth splined shaft end AW1122BCD R SP Right hand 1 1 2 diameter 14 tooth splined shaft end AW1118B Left hand 1 1 2 diameter 3 8 square keyway shaft end AW1118B R Right hand 1 1 2
13. 3 35 Patek f Perv nero 1 7 crosshead Asentiy PPFWCtass 3 or Fuin Chamber PPRICIGBATTT 1 Te Side PPNCsos 3 988 vaese pPrwc 204740 6 9 oise Psonroa PPro nirre o S Olde PPRICUSHS 3 10 SeaRetanernut PPFMC 126323 3 4M Peono PPRICABMMN 3 i T Gasket Soa Retaner PPFNCo 3 B PsonHode Perme 1278125 3 12 Beating Housing Bind Parwo 248360 2 42 Hex Permesso 3 19 T enim Bearing Housing PPFMC 1252598 6 49 Pungernat PPRICAWMS 3 M Gasket Bearing Housing PPFMC ASIeTS 2 MB Psion Retaner PPrwC 1207280 3 PPFMC P508969 a 45 O Ring Rod Seal PPFMC 1101176 Tw ase ecko Permo Psoe 1 4 Gate Fu yn PPNCTNUS 6 ir Finonowing Dive Perwcszsrase 1 47 SuiF dCymdr PPRMCAWISD 2 18 Prion owing Bim Peruc Psoe 1 45 hena PPRHCTEISS 6 6 Oise Rum Peu 1 49 Vane coer PPRICEBSIO 3 Co eases Pron PerMCae 2 50 Gasket Vane Cover PPFMC 1279675 3 3 scewset Prve tessa 3 s1 Clamp Vave Cover PPHMCAR 3 Ca Nanette PPAMAKOAGeNU 52 Sud Vane Corer PPRMCAS S 6 79 Bearing Cone Crank PeRMCtTMIS 2 53 Hex Vane Cover PPRMCTIZST 6 M eating Cup Cek Perwcrsrrars 2 54 CyinderCover PPRMCTHSH2 3 25 Beating Pon PPHMCPStTr 2 55 Gasket Cyinder Cover PPHMCIZISD 3 x key Pero 1 55 SwknPuy Pe
14. 4 DEL Stud Cylinder Cover PPFMC 1279602 Au Plate 29 O Ring Bearing PPFMC 3226710 2 59 Valve Ball PPFMC 1101419 6 AW1122D AW1122BCD AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 53 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts AW1118 Component Parts List To order service parts or see exact component configurations for your particular pump refer to the cross section parts drawing in the literature kit supplied with the pump Contact your local American Mfg Company pump distributor or American Mfg Company if you do not have this information Figure 8 AW1118 Power End Components Qe 09 m GC e 26 19 G3 GA RD 2 77 M j 7 prom roy a SEEN Ey J 2 SS ND Y INSSNSSSSNSSSSSN WZ i Lo DELILE ELTON SSS a man uM N OI G z X 1 4 S Co oh GOG B TER 7 D om 2 EAN uu S Hel ZA LE ei LX i E i X VSN 00 94A NVO Pp pm TE AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 54 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Figure 9 AW1118 Power End Components e8 W GO G2 16 Storr E 77 I HI DIAM CX s o N N i N CBS de amp AW11 Pump Family Operations and Maintenance Man
15. 5 1122 Componeni Paris isle tire dide PnIFS E atiende aede IsM ONE 49 AWITIS Component Pans Hil eater eet eei tetummat bride epu eee ee E 54 Chapter CRON CI CO Lasuooenotums ie itane pesas nvUtessas s NUM det ECE EE ETETE qun E ueden d 62 Information about Your Pump sssssessee IH IH IH mH mene eere ne nee eere nns 62 MAGIDIeHndDCce Log occiso unte ateN Map HME UII E E SIM DURD MIU MINOR MEE 63 AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 4 of 64 A American Mfg Company Quality Mud Pumps and Parts List of Illustrations Figure AW1122 Pump Assembly with Pinion Shaft Figure 2 Discharge Line Gauges and Valves ccessssccccceeeesesessneeeeeees Figure 3 Using the Knock Out E9o0L 5c tibt ipit etre ina addon eins eos Figure 4 AW1122 Power End Components eeeeeeeeeeeeee Figure 5 AW1122 Power End Components ene Figure 6 AW1122D Fluid End Components eee Figure 7 AW1122BCD Fluid End Componentts cccssssseecceeeeeeeeeees Figure 8 AWI1118 Power End Components eese Figure 9 AW1118 Power End Components 12 e Figure 10 AW1118D Fluid End Components Figure 11 AWIIISB Fluid End Components eeeesseeeee Figure 12 AW11 Spline Shaft Components seeseeeeeeeee Figure 13 Pomp Mount Bot Patteri sisi
16. Family Operations and Maintenance Manual Revision 2 page 51 page 52 page 53 page 56 page 57 page 58 page 59 Page 35 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 1 Remove the cylinder cover clamps ltem 57 and cyl inder covers Item 54 as described in the Servicing the Pistons section page 32 Remove the outside cor ner fluid cylinder nuts Item 48 if they are still in place 2 Rockthe fluid cylinder fluid chamber to loosen from the cylinders liner Item 39 and then pull free of the fluid end studs If the pistons have already been removed take care to ensure that the cylinders liners do not fall off of the front of the power end and become damaged 3 To remove the piston assemblies see the Servicing the Pistons section page 32 4 Inspect all parts for signs of wear or damage Replace parts if required 5 Always replace the cylinder gaskets Item 46 when the cylinders have been moved or replaced 6 Tore install reverse the preceding steps Torque all fasteners as listed on page 30 lt is important to note that if the nuts Item 48 on the fluid cylinder studs Item 47 are not properly torqued a failure is likely AW11 Pump Family Operations and Maintenance Manual Revision 2 ANMI Page 36 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Replacing Valves A WARNING Disc
17. High Ambient 100 F to 130 F Texaco Meropa 68 90 0 40 Shell Rotella T Temperature 38 C to 54 C Shell Omala 220 15 0 100 synthetic SAE 5W 40 Service Shell Rotella T SAE 50 217 40 Mobil SCH 630 Exxon HD 3 50 wt 29 9 100 Mobil Trans HD 50 3e Cold Ambient 0 F to 30 F Texaco Meropa 68 90 0 40 Shell Rotella T Temperature 18 C to 34 C Shell amp Omala 68 15 0 100 synthetic SAE 5W 40 mene DA e 12 0 100 BP Vanellus E8 ULTRA 5W 30 Mobil Trans HD 20 eS d Mobil SCH 626 10 9 100 Frequent Texaco Meropa 150 Start Stop Operation Miscellaneous Lubricants Manufacturer Brand Name Internal Rust Cortec VCI 329 Inhibitor External Rust Texaco Metal Preventative Protective Oil L AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 27 of 64 Synthetic lubricants are suggested for high or low temperature service Cortec is a registered trademark of Cortec Corporation St Paul MN A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Oil Changes The oil must be changed after the first 100 hours of operation and thereafter every 4 000 hours of operation or every 6 months whichever comes sooner These intervals may be modified de pending on actual operating conditions The AW11 pumps require 4 quarts 3 8 liters of oil The oil should be changed when hot to prevent the build up of sludge deposits A WARNING Be aware of the oi
18. Maintenance cccccscsccscceccecceccecescceceeceeceeceeceeceeceeceeceeceeceeceeceecaeeeees 25 Inspection and Preventative Maintenance sssssssssssssseseneen ee eene mene nnns 25 EUDUICallIORsecesortimtire ETERNI PIN ENS UMP Ue E Ub NUPNUDAF EEUU NIIS MENS 27 Recommended Lubricants cccccesscessecesscessecesecessecesecessecesecessecssecesecesscesseceseeesseessseenseeaes 27 OI CHANGE RII u M 28 Important Maintenance Information sess eene nennen rennes 29 Critical ClEGrance cccccccessccsssecessecessecessecessecessecessecessecesseceeseccessecessecessecessesensesensesenseeenses 29 Torque Requirements ccccccccecsssssssceeececeeeeesssseeeeeceeeeeeessssseeeecceceesessesseeeeeceeeeeesssaeeeeeeeeeeeees 30 Specialized Service Tools ueeprsesumsste estos imde ted iuvE Sept rbevlbx Urb uber bead o I4 dM EUPSU DET P rMIrOSN 31 DEF Tel are INe AIO B TETTE EET T 32 REMOVING the Fluid Cylinder cisoscdsenccssocnsnasaccasieacnonandesoesnaweracdowrtinanedstadsbdeasawtaasneedeoss 35 Replacing VAVE NETT ET TT E ETT TTE 37 Servicing the Power End sese cctnecssccntaneaensuessalssindnwwedsannevnontinenehanontcsandeusansawsateteedness 40 Replacing Piston Rod Oil Seals sese 40 Replacing the Power End Bearings and Crankshaft sese 42 Chapter 7 Spare Parts Additional Products sees 48 Ordena GUS eE E aeta euni ipM MEE MEM MH NE NUN EAM 48
19. Pump Family Operations and Maintenance Manual Revision 2 ANVI Page 21 of 64 a American Mfg Company Quality Mud Pumps and Parts Chapter 5 Troubleshooting Chapter 5 Troubleshooting Table 3 Troubleshooting No flow at all from pump Low pressure from pump flow OK Low flow from pump pressure OK Low pressure low flow rough operation No flow to the pump Inlet strainer clogged Pump crankshaft is not being rotated Pump speed too low The relief valve is out of adjustment or worn Worn nozzle low system resistance Problems with check valves Leakage from pump seals Pump speed is too low The relief valve is out of adjustment or worn Worn valves pump Work piston s or plunger s Valve seat bad or washed out Not all cylinders are primed Bypass or relief fluid is piped back to suction Inlet line insufficient for desired flow Insufficient NPSHA Air leaks Vortex near inlet pipe opening in tank affects flow to pump Air in booster pump Pump valve is sticking damaged or un seated Valve seat bad or washed out Gas pockets forming due to high spots in action AW11 Pump Family Operations and Maintenance Manual Revision 2 Ensure lines are connected to the pump the liquid supply is ready and the proper valves opened Clean or replace strainer Check pump drive mechanism and connec tions Increase speed check belts for slipping power
20. Suction Head available NPSHa ex ceeds the pump Net Positive Suction Head Required NPSHr by at least 5 feet 1 5 meters of water for proper operation of the pump NPSH requirements for each pump model are provided on the product data sheets available through American Mfg Company or your au thorized American Mfg Company reseller American Mfg Company does not recommend us ing the pump in static lift conditions without prior factory approval AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 13 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Recommended Discharge Piping Poorly designed or implemented discharge piping is also the root of many pump problems Here are some recommendations to follow in designing or construction the piping from the pump e Design the discharge piping to have as short and direct a route as possible Use the same pipe size as the outlet of the pump in installations where the discharge piping is in excess of 50 feet 15 meters use the next larger size pipe to minimize friction losses downstream of the pump W Aag Always use pipe or hose that is designed for your particular pres sure requirements Inadequate pressure ratings can allow hose or pipe to fail resulting in equipment damage and possibly personal injury Normal hose pressure ratings are clearly marked on the outer surface of the hose Working pressure ratings fo
21. Vives PPrwc 204740 6 10 seaiRetanernut PPFMC 126323 3 3 Olde PPICUSINS 3 i Gasket seaRetaner PPro azene 3 40 Peono PPRICABNN 9 tz Beating Housing ind FPFNCiMGNS 2 4 PsonHo e PPRCAMS 3 13 stim Bearing Housing PPFMC 1252508 6 a2 henu Permesso 3 wo Gasket Bearing Housing PPFMC A91675 2 4 Plunger Nut PPFMC A5016 EJ is co Memes 1 M PeonRetane Peruo ersa o 18 Gasket BackCover perc Poos 1 5 O Ring Rod Sea Pervo monre 3 ir Pinion Housing ore PPFuCsosrs 1 46 Gastet Fui Cynder Perme 1270676 6 16 Prion Housing ind PPFUC Psosote 1 4 Sud Fuit Cynder PPRICAWEID 2 19 oneal Roig PPro sars 1 4 amp hent perve narsa 8 a0 caste Prion prrucastere 2 49 VieCme pPrwc aestia 3 Ca soens PPro neo 3 S Gastet Vave Cover Perme 1279675 3 z Name Pate Pamano 1 st Camo vave Cover PPRICABES 3 zm NanePate _ prrucsarree 1 S Sha vavecover Peruc asore 6 7 Bearing Cone Crank PPFMC 177473 2 59 HexNut Vave Cover PPRICI2IST 6 a Bearing Cup Cra PPFMCaTTa74 2 9 OferOme PPFWCTDeStI2 3 5 Bearing Prion PPFUCPSti74s 2 SS Gastet Oyinder Gover PPFWC T270674 3 m ey oo 1 56 SucionPuy PPRICHOSI 3 a GmssewPhonBesng PPFMC 1100064 12 Sr Clamp Oyinder PPRICAMENZ 3 E Cap Screw Inspection PPFMC 110080
22. and simplify these tasks when they are required Regular inspections allow operators to become familiar with normal pump operation so they can recognize the signals of potential problems and schedule the required maintenance The Pre ventative Maintenance Chart in Table 4 shown below should be used as a guideline only many applications will require adjustment of the intervals shown in this chart for severe or unusual op erating conditions AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 25 of 64 American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Table 4 Preventative Maintenance Chart interval Component sorice Remarks Break In Period Crankcase Oil Change Drain and refill with new oil after first 100 hours of opera tion Clean the magnetic drain plugs to remove debris Inlet Strainer Inspect Clean if required The amount of material in the strainer will determine the interval of cleaning Complete Pump Inspect General inspection of pump and system to check for proper operation of equipment Piston Cup Sets Inspect Check the cylinder liner area of the pump for signs of leakage Replace piston cups if leakage becomes exces sive Pump System Flush Required for shutdown when pumping fluids that may harden or corrode the pump if left inside once stopped Crankcase Oil Inspect Ensure that the oil is at proper level and has not been contaminated by pumpage or condensation
23. cceleration head in suction line Service replace gears Provide more Net Positive Suction Head Improper charge of pulsation dampener Install a suction stabilizer Inlet line insufficient for desired flow Set for proper pressure Worn piston seal air enters pump More Increase pipe diameter and or shorten run likely when booster not used Service Replace seal s Piping vibration Same as rough operation above Same as rough operation above Excessive pressure variation in discharge Install discharge pulsation dampener Piping support inadequate Install pipe supports at proper locations Too many tight elbows or tees Correct installation to minimize turns and short radius elbows or other fittings Rapid suction pressure fluc Pump cavitation Increase suction pipe diameter or NPSH an Air is entering suction line Service Stop leaks Pump requires excessive Discharge pressure is too high Reduce system back pressure or add adjust power relief valve Speed too high Reduce speed Misaligned coupling Correct alignment Belts too tight Reduce belt tension Power end bearings too tight Increase end play Low motor voltage Supply correct voltage Power end overheats gt 180 Discharge and or suction pressure too high Reduce pressure F and or shortened life for power component end Oil level too high or too low Adjust to correct oil level Oil in the power end is contaminated Refill with clean oil amp stop c
24. diameter 3 8 square keyway shaft end 14 tooth 12 24 Diametral pitch female spline per ANSI B92 1 specifications Disclaimer Information in this document is subject to change without notice and does not represent a commitment on the part of American Mfg Company American Mfg Company provides this document as is without warranty of any kind either expressed or implied including but not limited to the particular purpose American Mfg Company may make improvements and or changes in this manual or in the product s described in this manual at any time This document could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes may be incorporated in new editions of the publication AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 2 of 64 A American Mfg Company Quality Mud Pumps and Parts Table of Contents WIS Or COMON eE E E E EEE 3 ASE Or HUSNOO o eE E E TT 5 Listot Tables and Charis EI ETE TE TT 5 Cligpler T aoaea E E ETE E E E 6 DTS I SPIO Gear E E E EE E E E T I 6 Safety When Using the Pump sessssssssseseeee e II Ie e I n nemen mee nennen en eere ens 7 Safety when Working on the Pump essessessesee HH Ie menn e e nennen 8 Personal Protective Equipment wiiscaascadiactconscaenssndscodnasaaoiassedsaidaaswenainavtewnesredeassarcadonebes 9 Chapter 2 Product DeSCription ccscccecsecsecececceceeccecececec
25. ditional Products Quality Mud Pumps and Parts AW1122 Component Parts List To order service parts or see exact component configurations for your particular pump refer to the cross section parts drawing in the literature kit supplied with the pump Contact your local American Mfg Company pump distributor or American Mfg Company if you do not have this information Figure 4 AW1122 Power End Components eA 69 7 C G Q9 Q9 G9 GA RI Q2 Zt Zi Ses Wine FETA Iu eccl ee mm A W WILL TER Ign AT 1l Prep e Zitttststithdhiiitibitidibit fe AT TE AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 49 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Figure 5 AW1122 Power End Components e9 CD GIGI C2 t6 es ams ont uz rrr d AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 50 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Figure 6 AW1122D Fluid End Components 6020 49 5349 2 3 Bar 7723 I lt 4 PZN EA A Ne AN NY J SAEPE V T aE ee amp GO amp 8 9 p X A M S NN SS 7 wa A iec WwW f Nee NY M2222 2222 _2P 222222 2 n EX SQ amp AW11 Pump
26. e 1 500 DIA SHAFT LH OR RH 7 312 AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 64 of 64 Poe VA
27. e and toxic Observe all of the safety instructions on the solvent packaging Never attempt to modify the pump to perform beyond its rated specifi cations without proper written authorization from American Mfg Com pany Mfg Compa ny Chapter 1 Safety A American Mfg Co m pa ny Chapter 1 Safety Quality Mud Pumps and Parts Personal Protective Equipment Personal Protective Equipment must be worn in accordance with Occupational Safety and Health Standards standard number 1910 132 138 Protective equipment including personal protective equipment for eyes face head and ex tremities protective clothing respiratory devices and protective shields and barriers shall be provided used and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment chemical hazards radiological hazards or me chanical irritants encountered in a manner capable of causing injury or impairment in the func tion of any part of the body through absorption inhalation or physical contact AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 9 of 64 A American Mfg Company Chapter 2 Product Description Quality Mud Pumps and Parts Chapter 2 Product Description The AW1122 pump includes the integral gear reduction pinion shaft Standard features per model are specified in the table below Pump Models This manual covers the American Mfg Company Mode
28. e power end crankcase oil and remove the oil fill cap or plug Pour to 1 cup of internal rust inhibitor oil into the oil fill hole then install the filler cap e Coat all exposed unpainted metal surfaces for example the driveshaft with preservative oil e Replace the oil fill cap and then cover the entire pump with a weather resistant covering such as a canvas or plastic tarp AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 16 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Long Term Storage Long term storage is defined as any period when the pump is in storage or idle in excess of six months e f the pump has been in service drain any fluid from pump fluid end flush the fluid end with water to clean out any of the remaining pumpage and blow dry with compressed air e Pour 1 4 to 1 2 cup of internal rust inhibitor oil described in Table 5 Recommended Lubri cants page 27 into the suction and discharge ports of fluid end and then install pipe plugs In openings e Remove the piston cup seals as described in Servicing the Pistons page 32 seal them in a bag to protect against ozone and store them in a separate location with a controlled envi ronment where they are protected from UV exposure e Drain the oil from the pump power end Remove the rear cover to expose the drive compo nents Spray all internal parts with a rust preservative that
29. e pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause elec trical shock or injury from moving pump parts or components under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Pump on page 8 A Review all of the safety warnings listed in under Safety when Working on the The fluid chamber Item 37 may be removed to inspect for internal damage to be repaired to replace the fluid cylinder to replace damaged cylinders cylinder O rings or to service piston rod seals If possible always pump a sufficient quantity of clean water through the fluid end before starting any service procedures that involve fluid end components This action will remove a significant portion of contaminants left in the fluid cylinder by the normal use and improve the ability to work with parts or see potential problems For item numbers see AW1 122 Figure 6 AW1122D Fluid End Components Figure 7 AW1122BCD Fluid End Components Table 9 AW11 Component ltem and Part Numbers AW1118 Figure 10 AW1118D Fluid End Components Figure 11 AW1118B Fluid End Components Table 10 AW1118D Component Item and Part Numbers or Table 11 AW1118B Component Item and Part Numbers AW11 Pump
30. earing cones with the cutouts in the power frame and pull out of the back Handle the crankshaft very carefully to prevent critical bearing surfaces from being scratched or damaged 32 The bearing cups Item 24 may be removed from the crankshaft The bearing cones Item 23 can be removed from the bearing housing by using a puller if a sufficient lip is available for the puller arms to grab Alternately a weld bead can be run around the inside surface of the cup when cool this will reduce the interference between the cup and bearing housing enough to free the cup If either the cup or cone is replaced the corresponding cup or cone should be replaced as they are a matched set 33 Pull the connecting rod crosshead assemblies Item 7 from the power frame Mark each connecting rod and crosshead assembly to make sure you can reassemble them into the same bore from which they were removed 34 If either the crosshead or the connecting rod requires service remove the set screw Item 21 and slide the wrist pin Item 6 out of the crosshead Item 7 Again keep the components matched together 35 Inspect all components and replace any worn or damaged components remembering to replace matched components in pairs Carefully check the crankshaft bearing sur faces for pits scratches or other signs of wear The connecting rod bearings should be inspected for deep scratches or for the top metal surface being worn away AW11
31. eceecececsecseceecseceees 10 Pomp aee PTT TRITT TETTE DU 10 AWITI Pomp OCC NOOO Six ever bre imenedien EEA E UTE T RIP NEN EERS 11 Peitormanese Beli saccaestocrdesctuepdantenden anes sant EE EES EEEE EE RUPEM ae UP EDU NI 11 Chapter 3 Installation and Storage csccsscsecseceecececsecececececsececsecseceeceeeeees 12 Installation G70 lo M BIETET TTE TT TODO TTE 12 LSA ibe PUMN e OE ET 12 Mounting The P Tips cases qonisudtaONI ic EE edie can MU TN ERU EMEUDU PME EU E 12 Suction Piping RECOMMENCATIONS sccscceeceeceececeeececeecceececceceeceeceeceeeaeeaeeaeeneeeeenees 13 Recommended Discharge Piping cence coat ncnccasneecteconsedecnessaet E EEEE ETE 14 SIoradge WAST C1 ONS e E EEA EEA E A E EE EOE 16 O TET N gE e E m T T m DAE ANE TA 16 Short Term Storage for Severe Environments sss 16 Long BE dnt Rio ges NR TN 17 Returning a Stored Pump to Operation sessssseseeeee eene nennen ener 17 Precautions during Freezing Weoather sse eene ener 18 Chapter 4 Operation a en eee EID 19 How TOOIBr THe PUE oscar E E E SINIT edad Sum M Io D CA eM 20 Pump Starting Procedure m NT 20 Dunno 01 1 6 o aeaniee E EA 21 Chapter 5 Troubleshooting 0 0seseseseesesesessesesesessesesesessesesessesesesessesesesessesesesesses 22 Contents AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 3 of 64 A American Mfg Company Contents Quality Mud Pumps and Parts Chapter 6
32. ed equipment has been installed and properly adjusted Verify that all joints are pressure tight Make sure that all guards are in place and secure Verify that all personnel are in safe positions and that system conditions are acceptable for operation Check to ensure that power is locked out and tagged out Open the suction line valve to allow fluid to enter the pump Prime the fluid cylinder if necessary on the initial start up or after the system piping has been drained The valve covers may have to be cracked open to assist with priming Apply 10 to 20 drops of glycerin or mineral oil to the pistons cylinders and piston rods to lubricate the packing and seals Turn the pump over by hand if possible to ensure free unobstructed operation 10 Remove the tag out and unlock the power AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 20 of 64 A American Mfg Company Chapter 4 Operation Quality Mud Pumps and Parts 11 The pump is now ready to start Whenever possible use a bypass in the discharge line to allow the pump to start in the unloaded condition no discharge and pressure Slowly close the bypass line to bring the pump into full load conditions During Operation Shut down immediately if the flow becomes unsteady pressure fluctuates or if unusual sounds or vibrations are noted Take periodic temperature readings of the power end Do not exceed 170 F 77 C on the power end AW11
33. emove the hex piston nut Item 42 from the piston crosshead rod Item 7 This nut secures the piston assembly to the pis ton crosshead rod 3 Next use the American Mfg Company piston tool PPFMC A5049 to pull the piston assembly from the cylinder Item 39 Insert the American Mfg Company piston tool inside the cylinder until flush with the face of the slotted piston retainer nut Item 43 Twist the tool to engage and lock the tabs of the tool inside the mating slots in the retainer nut 4 Using a combination pulling and twisting motion pull the piston assembly free of the pump AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 33 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 5 Place the flats on the bottom of the piston holder Item 41 in a vice and clamp them securely Using the American Mfg Company piston tool PPFMC A5049 unscrew and remove the piston retainer nut Item 43 The piston cup Item 40 and piston retainer Item 44 may now be removed 6 Inspect all parts for damage or unusual wear Ensure that the interior surface of the cylinder Item 39 is smooth and free of cracks or grooves New piston cups will fail prematurely if installed in liners with damaged bores American Mfg Company strongly recommends that all three piston cups be replaced not just those that show signs of leakage whenever this type of service is performed Th
34. er 2 3 4 HSN Piston Rubber 2 3 4 Carbox Nitrile XNBR ee NN _2 114 Rubbers AW1118 Pumps Standard Rubbers DO Piston Rubber 2 1 4 Neoprene standard production part Alternate rubbers BS Piston Rubber 2 1 4 Carbox Nitrile XNBR AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 61 of 64 A American Mfg Company Chapter 8 Reference Quality Mud Pumps and Parts Chapter 8 Reference Information about Your Pump Fill in the blanks below with the key information about your specific pump model this informa tion will bake it easier to order parts The information is stamped on the metal nameplate on the pump power frame Pump Model Part Number Serial Number Rated Pressure Rated Capacity Rated Speed Other notes AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 62 of 64 A American Mfg Company Chapter 8 Reference Quality Mud Pumps and Parts Maintenance Log Date AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 63 of 64 A American Mfg Company Chapter 8 Reference Quality Mud Pumps and Parts Figure 13 Pump Mount Bolt Pattern 1 1 4 NPT DISCHARGE PORTS 2 PLACES 10 120 2 875 COUNTERBORE WITH TAP 5 8 11UNC 9 750 INQ LA 2 875 COUNTERBORE WITH 11 750 i TAP 5 8 14UNC 2 BERT TIN PORTS TAP 5 8 11UNC gt B00 4 125 3 PLACES 1 000 C Y 0 375 h
35. erican Mfg Company can factory prepare units for long term storage for a nominal fee if specified at the time of order AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 17 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Precautions during Freezing Weather Freezing weather causes problems tor equipment when pumping water based fluids that expand in volume when frozen When water left in a pump fluid end is frozen it can rupture the fluid cylinder of the pump and cause extensive equipment damage A WARNING Injury may result when starting a pump that has been damaged Whenever the pump is stored or is idle in conditions that are near or below freezing ALL water based fluids should be removed from the pump 1 Run the pump for a few seconds with the suction and discharge lines disconnected or open to atmosphere This will clear the majority of the fluid from the pumping chamber suction manifold and discharge manifold 2 Blow compressed air through the fluid end to remove all traces of fluid 3 Remove the cylinder head and lift up the discharge valves Remove the plugs from the bottom of the fluid cylinder and lift up the suction valve to ensure that all fluid is drained from the pumping chamber between the suction and discharge valves 4 As an alternative to the previous three steps a compatible antifreeze solution can be cir culated through the fluid e
36. es that sufficient clearances exist 7 Remove the three suction plugs Item 56 from the bottom of the fluid chamber Item 37 AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 37 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 8 Remove the six valve cover nuts Item 53 holding the valve cover clamps ltem 51 then remove the three valve covers Item 49 from the fluid cylinder 9 Removing the cylinder covers Item 54 allows access for inlet valve removal Remove the cylinder covers as described in the previous procedure Removing the Fluid Cylinder page 35 10 Removing valves e For disc valves use knock out tool PPAM A000399000 e For ball valve seats use knockout tool PPAM A000233000 Insert the tool from the bottom of the fluid cylinder and push up until it is stopped by the bottom of the valve seat Strike the tool sharply with a hammer to loosen the valve seat First remove the suction valve seat through the cylinder cover then the discharge valve seat through the valve cover Figure 3 Using the Knock Out Tool Strike on this end with a hammer to remove the valve AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 38 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Installation of valves 11 The suction valves must be installed before the discharge valves can be insta
37. f 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Checking Crankshaft End Play with a Dial Indicator 49 Mount the indicator base on the power frame with the indicator tip on a machined shoulder surface of the crankshaft do not measure from a cast surface Align the axis of the indicator parallel to the crankshaft Set the dial indicator to zero Move the crankshaft back over to the opposite side and read the bearing end play as total indicator movement Rotate the crankshaft several turns then repeat moving the crankshaft in the direction described in this step Repeat the dial indicator measurement Remove or add shims as necessary to achieve proper endplay 002 tight to 003 loose Distribute the shims equally on both bearing housings Verify the endplay with the dial indicator before final assembly Reassembly continued 52 Install the oil seal Item 19 into the bearing housing Item 12 The oil seal can be installed with light hammer blows When properly seated it will be flush with the face of the bearing housing 53 Install the piston rod seal holder Item 9 and the seal retainer Item 8 in the power frame per the instructions in Replacing Piston Rod Oil Seals on page 40 The crank shaft Item 2 should turn freely 54 Complete the reassembly of the pump A tool PPAM A000387000 can be purchased to aid in the assembly of the pinion bearing if needed 55 To
38. fg Company s world wide network of distributors Table 8 American Mfg Company Service Tool Part Numbers Tool To Tighten Packing Nut Tool To Press In Seal On Pinion Caps Tool Bearing Press For Pinion Tool For Housing Cup Press Tool Hand Crank Pinion Tool Disc Valve Seat Driver Tool Ball Seat Driver Tool Piston Nut Remover Tool Ball Magnet AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 31 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Servicing the Pistons A WARNING Disconnect the pump from the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at the pump n Adaa If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause elec trical shock or injury from moving pump parts or components under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Review all of the safety warnings listed in under Safety when Working on the A Pump on page 8 If possible always pump a sufficient quantity of clean water through the fluid end before starting any service procedures that involve fluid end compone
39. he rod With the gasket Item 11 and seal holder Item 8 in place install the seal retainer Item 10 and tighten until it bottoms out Do not over tighten as it can damage the seal retainer gasket Remove the protective material that is covering the rod threads Rebuild the remainder of the pump as outlined in previous sections Torque all fasteners to the torque specifi cations listed on page 30 AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 41 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Replacing the Power End Bearings and Crankshaft Disconnect the pump from the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at the pump If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause electrical shock or injury from moving pump parts or components un der high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Review all of the safety warnings listed in under Safety when Working on A the Pump on page 8 For item numbers see AW1122 Drawings starting on page 49 Table 9 AW11 Component ltem and Pa
40. is soluble in lubricating oil while rotating the driveshaft several turns by hand to ensure complete coverage Replace the rear cover and add 1 2 to 1 cup of internal rust inhibitor described in Table 5 page 27 Spray a rust preventative onto all exterior machined surfaces paying attention to any unpainted areas like the crankshaft extension Remove the oil fill cap and store with the piston cup seals Cap the breather opening with a plug or other suitable means in order to keep the preservative atmosphere sealed inside the power end e Never store the pump on the floor or ground Always place it on a shelf or pallet that is sev eral inches above ground level Cover the entire pump with a canvas or plastic tarp Every two months inspect the unit Rotate the crankshaft by hand at least 4 turns during each in spection Drain and replace the rust inhibitor after every six months of storage Returning a Stored Pump to Operation Before operating a pump that has been prepared for storage drain the preservative and lubri cating oil mixture from the power end crankcase Remove the rear cover and apply recom mended crankcase lubricant see Table 5 Recommended Lubricants page 27 to the pinion bearings Reinstall the rear cover drain plug breather filler cap piston cup seals and any other components that were removed for storage Once these steps have been completed follow the normal pump start up procedures outlined in this manual NOTE Am
41. is will maximize operational time between service intervals 7 Reverse steps 1 through 6 to rebuild the pump after worn or damaged components have been replaced American Mfg Company recommends replacing all seals and gaskets that are disturbed during the service procedures This includes the rod seal O ring Item 45 that is located on the piston crosshead rod shown directly behind the piston assembly AW11 pump models have the O ring in a groove in the piston holder instead of a separate seal holder O Ring Tip When reassembling press the piston assembly into the liner until the sealing lip has just entered the front of the liner Use a small amount of glycerin on the ID of the liner to help lubricate the piston during installation After the liner has been installed in the pump power frame drive the piston assembly fully to its stop using the American Mfg Company piston tool PPFMC A5049 and a rub ber mallet Lubricate the piston cups and piston rods during assembly 8 Torque all fasteners as listed on page 28 AW11 Pump Family Operations and Maintenance Manual Revision 2 ANMI Page 34 of 64 A American Mfg Company Quality Mud Pumps and Parts Removing the Fluid Cylinder A WARNING the pump Chapter 6 Maintenance Disconnect the pump from the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at If necessary lockout or tagout th
42. ithout crankcase oil and can be stored as is for periods of up to six months in proper environmental conditions Indoor stor age in a dry temperature controlled location is preferred e f pumps are to be stored short term less than six months in a severe environment prepare them by following the procedure Short Term Storage for Severe Environments on page 16 e f the pump is to be stored or is inactive for periods in excess of six months prepare the pump as described in the procedure Long Term Storage page 17 Remember that any fluid that poses an environmental hazard or is toxic must be handled and disposed of properly Short Term Storage If the pump is stored in an indoor temperature controlled environment for less than six 6 months no special steps are required to prepare it for storage As a general rule for pumps used in corrosive fluid applications the fluid end should be drained flushed with water or other non corrosive cleanser and compressed air used to blow dry whenever idle Short Term Storage for Severe Environments e f the pump has been in service drain any fluid from pump fluid end flush the fluid end with water to clean out any of the remaining pumpage and blow dry with compressed air e Pour 1 4 to 1 2 cup of internal rust inhibitor oil described in Table 5 Recommended Lubri cants page 27 into the suction and discharge ports of fluid end and then install pipe plugs In openings e Drain th
43. l AW1 122 triplex piston pump and other pumps in the AW1122 family Valves Model Pir ion Shaft Shaft End Disc AW1122D Left hand 1 1 2 diameter 3 8 square keyway shaft end Disc AW1122D R Right hand 1 1 2 diameter 3 8 square keyway shaft end Disc AW1122D SP Left hand 1 1 2 diameter 14 tooth splined shaft end Disc AW1122D R SP Right hand 1 1 2 diameter 14 tooth splined shaft end Disc AW1118D Left hand 1 1 2 diameter 3 8 square keyway shaft end Disc AW1118D R Right hand 1 1 2 diameter 3 8 square keyway shaft end Ball AW1122BCD Left hand 1 1 2 diameter 3 8 square keyway shaft end Ball AW1122BCD R Right hand 1 1 2 diameter 3 8 square keyway shaft end Ball AW1122BCD SP Left hand 1 1 2 diameter 14 tooth splined shaft end Ball AW1122BCD R SP Right hand 1 1 2 diameter 14 tooth splined shaft end Ball AW1118B Left hand 1 1 2 diameter 3 8 square keyway shaft end Ball AW1118B R Right hand 1 1 2 diameter 3 8 square keyway shaft end 14 tooth 12 24 Diametral pitch female spline per ANSI B92 1 specifications Figure 1 AW1122 Pump Assembly with Pinion Shaft Oil Filler Discharge Plug Fluid Chamber Valve Covers B NM NM BB Input Shaft Rotation Cylinder Input Shaft Clamps EEUU E Suction lt Power End Fluid End em Plugs AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 10 of 64 American Mfg Company Quality Mud Pumps and Parts Chapte
44. l and power end temperatures to avoid scalding or burns e Check the oil level daily If more than 10 of the total capacity has to be added check for oil leaks e Do not mix oils of different types even if produced by the same manufacturer e Never mix mineral and synthetic oils e Follow environmental guidelines when changing and disposing of lubricants AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 28 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Important Maintenance Information Make sure you review the information in Critical Clearances page 29 and Torque Require ments page 30 as part of your servicing procedure If possible always pump a sufficient quantity of clean water through the fluid end before starting any service procedures that involve fluid end components This action will remove a significant portion of contaminants left in the fluid cylinder by the normal use and improve the ability to work with parts or see potential problems Critical Clearances When any maintenance requiring disassembly of the power end is performed check the follow ing clearances to ensure that they are within factory specifications or are within the maximum allowable component wear limits A maximum of 002 additional clearance is allowed for component wear This additional clear ance can be added to the clearance values in Table 6 below For radial clearance use o
45. laced be tween the pump and pressure relief valve these may defeat the safety purposes of the relief valve AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 7 of 64 A American Quality Mud Pumps and Parts Safety when Working on the Pump AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 8 of 64 Danger of Explosion Pneumatic steam and hydraulic devices are under pressure Serious accidents or explosions may result from the incorrect removal of these devices Before removing the devices any pressure must be released Failure to do so may spray water or chemicals at high pressure or high temperature onto service personnel Installation work in high positions may create a danger of falling Use additional safety steps scaffolding etc provided for this purpose Never use machine parts for climbing If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause electrical shock or injury from moving pump parts or compo nents under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that the engine or motor cannot be started Use extreme caution when using solvents to clean or degrease equip ment Most solvents are highly flammabl
46. lled The same reassembly procedure is applicable for both 5A Select a valve and check to ensure the taper on the seat is clean 5B Clean the taper in the fluid cylinder and on the seat with a cleaning solution and a clean cloth Small scratches can be removed with steel wool or 100 grit emery pa per Remove all dirt grease oil water or any other contaminants trom the sur faces Do not oil the seats or the seating surfaces in the fluid cylinder Make sure that they are dry before installation 5C Position the valves seat directly over the mating taper in the fluid cylinder 5D Let the valves seat drop into the taper Make sure that the seat is sitting in the taper properly and not cocked to one side If the seat drops straight it will seize on the taper When correctly seated it cannot be pulled up by hand 5E Place the valves seat installation tool PPAM A000399000 or PPAM A000233000 on the top surtace of the valves Strike with a hammer three times to set the seat 5F Repeat steps A through E for the discharge valves 5G Drop balls into seats if applicable 12 After the disc valves or balls and seats have been replaced the valve cover should be reinstalled Place the valve cover Item 49 with the new gasket Item 50 in position then install the valve cover clamps Item 51 over the valve cover studs Item 52 Replace the valve cover washers if installed and the valve cover hex nuts Item 53 13 Torque the
47. n Discharge pressure too high Hydraulic shock cavitation or trapped air Discharge valve stuck closed Fluid freezing in fluid cylinder Material or manufacturing defect Bolt or nut not properly torqued Excessive piping loads on fluid end Discharge pressure too high Suction pressure too high Fluid freezing in fluid end Hydraulic shock due to cavitation Material or manufacturing defect Chapter 5 Troubleshooting Adjust the belt tension if applicable Reduce the relief valve pressure setting Clear obstructions Replace Replace O ring Service Properly tighten and torque the fluid cylinder bolts Replace Install strainer or filter Find reason and correct then replace the cup Change to correct cup Correct problem and replace cups Replace piston cup holder Replace cylinder liner Install strainer or filter Correct problem and replace damaged valves Correct problem and replace damaged valves Increase submergence or baffle to stop vor tex Pipe fluid back to reservoir tank Replace damaged components Reduce system back pressure or relief valve Correct piping system problem Replace Change procedure to drain fluid when cold Replace defective component Replace fluid cylinder and properly torque Add supports to piping Reduce system back pressure or relief valve Reduce suction pressure or plunger diame ter Change procedure to drain fluid
48. nd RV antifreeze propylene glycol is recommended for this purpose Remember that any fluid that poses an environmental hazard or is toxic must be handled and disposed of properly AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 18 of 64 A American Mfg Compa ny Chapter 4 Operation Quality Mud Pumps and Parts Chapter 4 Operation Always take special precautions when starting a pump for the first time or atter any extended shutdown Never assume that someone else has properly prepared the pump and system for operation Always check each component of the system prior to every start up Operate the pump only if this operating manual has been read completely and is well understood Wear the necessary ear protection and safety clothing Check the pump for any damage Immediately inform the responsible supe rior about trouble or dam age of the pump Do not begin or continue pro duction when problems are encountered Ensure that no unauthorized persons are located near the moving parts of the pump A properly sized and configured pressure safety device pressure relief valve rupture disc etc must be installed before the pump is operated Ensure that no valves are placed between the pump and pressure relief valve these may defeat the safety purposes of the relief valve Check all safety and guard devices protecting the operating from the pump and from other moving machinery Check
49. nd Storage Quality Mud Pumps and Parts Chapter 3 Installation and Storage Installation Guidelines Proper installation of the pump is essential for best performance a long service life and reduc ing downtime and maintenance costs Prepare your installation carefully and observe the fol lowing guidelines Location of the Pump Always position the pump on as flat level a surface as much as possible this is important for the pump s splash oil lubrication system For mobile equipment sewer cleaning trucks drilling etc park the truck or trailer on as level a surface as possible Whenever possible the pump should be mounted in a clean dry location with sufficient lighting and adequate space for easy inspection and maintenance Locate the pump as close to the suc tion source as possible to allow for the shortest and most direct routing of the inlet piping Mounting the Pump The AW11 pump must be mounted in a horizontal position only Secure the pump to the founda tion or other mounting surface using the four 4 holes provided in the pump base Make sure to check the drive motor or engine direction of rotation to ensure that the top of the pump pinion shaft rotates away from the pump fluid end when in operation IF you are driving the pump with a V belt make sure to double check the alignment of the sheaves after the unit is installed on its permanent mounting Tighten the belts to the proper ten sion as recommended by
50. ne half of the total diametral values shown in the table EE 19 3 Critical Clearance Table mm oo oenen Clearance rm Crosshead Cylinder Bore ID 3 1245 3 1260 79 3623 79 4004 Crosshead to Bore Clearance Max Total 0 127 O Crosshead Diameter OD 3 121 3 123 79 2734 79 3242 ID Wrist Pin Bushing Bore 1 2505 1 2515 31 7627 31 7881 Wrist Pin to Bore Clearance Max Total 0 0508 Clearances shown are total diametral values AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 29 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Torque Requirements Improperly tightened pump bolts or screws can cause pump leaks or failures Use a calibrated torque wrench for the critical bolts and screws shown in Table 7 refers to the item numbers in the drawings in the AW1122 Component Parts List see page 49 and Table 9 AW11 Component Item and Part Numbers page 53 Table 7 Critical Pump Fastener Torque Values Bolt or Torque Torque Screw Size Ft Ib m I 5 Pinion Housing Screws s axor 0000000 0 s vine atacvCiane 5 s VaveGovernut SSC AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 30 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Specialized Service Tools The following tools are available and may be purchased at American M
51. necting rod caps Make sure that rod caps are properly assembled with their mating connecting rod Torque the tasteners holding the end caps to the mating rod see page 30 for the torque specifications Use a back and forth pattern when tightening with a torque wrench After the cap screws are torqued a light strike to the cap with a rubber hammer will help properly seat the rod bearings 46 Use a dial indicator to adjust the endplay of the crankshaft Improper adjustment may result in excessive temperature noise and or reduced bearing life American Mtg Company recommends between 002 tight to 003 loose of internal axial clearance end play when properly assembled The final adjustment must be verified using a dial indicator This is described in later in this procedure under the heading Checking Crankshaft End Play with a Dial Indica tor on page 47 47 Turn the crankshaft three revolutions or more to ensure that the connecting rods are loose and that there is no binding in the rod bearings that the wrist pin joints are free and that the crossheads move freely in the power frame 48 Using a light tap from a rubber mallet or a pry bar move the crankshaft to one side of the power frame Rotate the crankshaft several turns and repeat the light taps from a rubber mallet or use of a pry bar to ensure the crankshaft is fully to one side AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 46 o
52. nts This action will remove a significant portion of contaminants left in the fluid cylinder by the normal use and improve the ability to work with parts or see potential problems For item numbers see AW1122 Drawings starting on page 49 Table 9 AW11 Component ltem and Part Numbers page 53 AW1118 Drawings starting on page 54 Table 10 AW1118D Component Item and Part Numbers page 58 or Table 11 AW1118B Component ltem and Part Numbers page 59 To service the pistons a minimum of two feet of clearance is required between the front of the pump cylinder cover Item 54 and any obstructions If there is insufficient clearance the pump must be removed and relocated to an area where adequate clearance exists AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 32 of 64 a A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts The following procedure is written under the assumption that sufficient clearances exist 1 To access the piston cup seals Item 40 the cylinder cover clamps Item 57 must be removed Remove six of the nuts Item 48 holding the cylinder cover clamps in place and then remove the cylinder covers Item 54 Do not remove the two nuts Item 48 on the opposite corners of the fluid cylinder as those two nuts keep the cylinders Item 39 and fluid cylinder mounted on the pump during this procedure 2 Using a socket wrench with a long extension r
53. ods The fluid end and cylinders must be removed as outlined in the previous sections to provide access to these seals 15 Rotate the seal retainer Item 10 counter clockwise until it is unscrewed from the frame then slide it off the rod Use a larger flat head screw driver as shown A tool PPAM A000385000 is also available AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 40 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 16 17 18 19 20 21 Pull the seal holder Item 8 out of the pump frame and slide it off of the rod Remove the seal retainer gasket Item 11 from the power frame Inspect the seals Item 9 and note the orientation of the seals prior to removal The old seals may now be removed from the seal holder and discarded To rebuild insert new seals Item 9 in the seal holder Item 8 taking care to en sure they are oriented in the same direction as the ones that were removed Never re use seals that have been removed from the pump Replace the seal retainer gasket Item 11 if it shows signs of wear deformation or damage Wrap tape or other material over the exposed piston rod threads to protect the new seal lips from damage Install the seal retainer gasket then slide the seal holder over the protected threads and into the pump frame Take care that the seal lips are not folded or cut when passing over the ends of t
54. onnect the pump from the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at the pump If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause elec trical shock or injury from moving pump parts or components under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Review all of the safety warnings listed in under Safety when Working on the A Pump on page 8 For item numbers see AW1122 Drawings starting on page 49 Table 9 AW11 Component Item and Part Numbers page 53 AW1118 Drawings starting on page 54 Table 10 AW1118D Component Item and Part Numbers page 58 or Table 11 AW1118B Component ltem and Part Numbers page 59 Disc or Ball type valves are used depending upon the pump model purchased Note A minimum of two feet of clearance is required above below and in front of the pump fluid cylinder in order to perform valve service without removing the fluid end of the pump If sufficient clearance is not available the fluid end must be removed see Removing the Fluid Cylinder on page 35 and taken to a work shop for valve ser vice The following procedure assum
55. ontamination Incorrect oil viscosity or grade Drain and refill with correct oil Misaligned coupling Correct alignment Drive belts too tight Adjust belt tension Pump running backward Correct rotation The pump is located too close to a heat Remove the heat source and or insulate the source power end Worn or damaged power end bearings Service Replace damaged bearings AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 23 of 64 American Mfg Company Quality Mud Pumps and Parts Problem Symptom Crankshaft jerks or starts and stops rotation Crankshaft jerks or starts and stops rotation Short piston cup life Short valve life Cracked fluid cylinder or bro ken fluid end bolts Broken crankshaft or connect ing rod Drive belts loose slipping if so equipped System relief valve pressure set too high Discharge line blocked or partially blocked Worn Piston cup s The piston to rod O ring is damaged The fluid cylinder bolts are not properly tight ened Fluid cylinder O rings or gaskets damaged Abrasive particles in fluid Piston cups run dry Incorrect cups for fluid type Pump was run dry for extended time Worn piston cup holder Worn cylinder liner bore Abrasive particles in fluid Damage from Cavitation Air leaking into suction line Suction inlet insufficiently submerged Relief valve or bypass piped to suction Valve damaged by improper installatio
56. r 2 Product Description 30 BHP Continuous Duty 36 BHP Intermittent Duty AW11 Pump Specifications Pump Models Configuration Duty Continuous Duty Intermittent Number of Pistons Piston Diameter otroke Length Displacement Frame Load Rating Pump Weight Direction of Rotation Internal Gear Rotation Intermittent Duty Speed Rating Continuous Duty Speed Rating Ball Valve Max Speed Rating Minimum Speed Mechanical Efficiency Lubrication System Lube Oil Capacity Lube Oil Type Maximum Fluid Temperature Minimum Fluid Temperature Maximum Pressure Standard Suction Size Standard Discharge Size Fluid End Material Valve Type Hydraulic Motor Mount AW1118 AW1122 Horizontal Triplex Piston 30 BHP 36 BHP 3 AW1118 2 25 57 2 mm AW1122 2 75 69 9 mm 2 5 Inches 69 9 mm AW1118 0 0589 gal 0 223 Liter AW1122 0 0589 gal 0 223 Liter 6000 Ibs 2 721 kg 425 lbs 197 kg Top of Shaft away from head 3 6 1 900 RPM Jackshaft 750 RPM Jackshaft 635 RPM Jackshaft 360 RPM 85 Splash Gravity Return 1 Gallon SAE 30 See Table 5 on page 27 140 F 250 Capability 0 F 20 Capability 1000 psi 70 3 kg cm 2 00 Inch NPT 50 8 mm 1 25 Inch NPT 31 8 mm Ductile Iron Disc Valves Ball Valves SAE C 4 Bolt with 1 25 14T AW11 Pump Family Operations and Maintenance Manual Revision 2 Performance Rating Pump Capacity Input Speed
57. r steel pipe can be obtained from the manufacturer or from the chart below Table2 Allowable Working Pressure For Steel Pipe PSI 100 F Note 1 BAR 14 5 p s i Pipe Size Pipe Schedule Number chen ae ea a5 3 1600 260 1 300 2 090 6 1210 2 070 2 850 3 760 4 660 8 1 00 1 870 2 840 3 700 3 560 e Always install a pressure gauge in the pump discharge line A properly functioning gauge mounted at the pump and before any valves is required to accurately determine the operot Ing pressure of a pump and assists in troubleshooting AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 14 of 64 American Mfg Company Chapter 3 Installation and Storage Quality Mud Pumps and Parts Ensure that all piping is supported independently of the pump to reduce vibrations and strain on the pump do not make the pump outlet one of the supports To help isolate mechanical and hydraulic vibrations American Mfg Company recommends the use of flexible pipe cou plings or hose connections between the pump and any rigid piping and or the use of pulsa tion dampeners Pulsation dampeners on the discharge are recommended to reduce pressure pulsation and resulting vibration Avoid as best as practical the use of elbows nipples unions or other fit tings For example instead of a short radius 90 elbows use two long radius 45 elbows Install and properly adjust a pressure relief valve or rupture
58. rain nnns neses List of Tables and Charts Table 1 Warning Code Symbols s 0 scasscsssansnsessencsdessaquatansnasaventacseasaceastene Table 2 Allowable Working Pressure For Steel Pipe Table 3 Troubleshooting eese Table 4 Preventative Maintenance Chatt ccccccsessssssessesessssseseeeens Table 5 Recommended LU Dime ais ius cctsncctesxcceessadnnntanaseesetandacasnedaiceessnedwent Table 6 Critical Clearance Table caet etre ret reet etes inates Table 7 Critical Pump Fastener Torque Values esssssse Table 8 American Mfg Company Service Tool Part Numbers Table 9 AW1122 Component Item and Part Numbers Table 10 AW1118D Component Item and Part Numbers Table 11 AW1118B Component Item and Part Numbers Table 12 AW11 Spline Shaft Component Item Numbers Table 13 Replacement Rubber Item Numbers eeeeeeeeeeeee AW11 Pump Family Operations and Maintenance Manual Revision 2 Contents ANVI Page 5 of 64 A American Mfg Co m pa ny Chapter 1 Safety Quality Mud Pumps and Parts Chapter 1 Safety Safety symbols These symbols are printed beside all safety instructions contained in this manual where poten tial danger to life and limb exist All operators must be fully informed of the safety instructions Table 1 Warning Code
59. re numbered codes stamped on each half of the con necting rod assemblies to help in keeping the matched sets to gether Don t forget to make certain they are installed in the same orientation when re assembling the pump TIP You may wish to make your own orientation marks on the connecting rod assemblies when disassembling the pump 28 AW1122 pumps use pinion shafts for internal gear reduction If the pinion shatt must be removed start by removing the hex head cap screws Item 27 and the left and right pinion housings Item 17 and Item 18 The gaskets Item 20 may adhere to the power frame surface they can safely be left in place if undamaged 29 Remove the pinion shaft Item 3 with its bearings by driving the shaft out with a mallet and brass rod or other soft material AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 43 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 30 Remove the hex head cap screws Item 27 bearing housings Item 12 O ring Item 29 and shims Item 13 from both sides of the pump Count and write down the number of shims on each side to facilitate assembly Again the gaskets Item 20 may adhere to the power frame surface they can safely be left in place if undamaged The O rings should always be replaced The bearing cones Item 23 will remain in the bearing housing 31 To remove the crankshaft line up the b
60. ro 1 7 crosshead Asentiy PPFWCtas 3 or Fuin Chamber PPRICIGBATT 1 Te Sese PPro 3 oen VaveAserby PPRCIZIMO 6 9 oisekPsonR PPro irre o 998 Olde PPRICUSMS 9 10 sealRetanernut PPFMC 1256323 3 408 Peono PPRICAMGN 3 Casket Seal Reamer PPFUCOOS 3 4iB Piton toer PPFMCTZIBUS 3 Shim Bearing Housing PPFMC 1252595 6 4 Plunger Nut PPFMC A5016 15 akCwe Paroso 1 45 ORngRoiSed Pervo nonr 3 46 Gee Fud Cyinder PPrUCT2reS 6 4 su Fud yinder prruCAstera 2 4 Wa fervents 8 n Stud Valve Cover PPFMCAS076 6 ET EN non Bear EN NM Cap screw Pinion Bearing PPFMC 1100054 Cap Screw Inspection PPFMC 1100804 Plate O Ring Bearing PPFMC 3226710 Stud Cylinder Cover PPFMC 1279602 ns Pini Bear AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 58 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Table 11 AW1118B Component Item and Part Numbers 1 PoverFrane PPrmosesre 1 30 Screw SefTanpng Prve teran 2 2 Torente _ PPFMC 204 1 ot Pate specion PPRMCSESOSGI 1 3 Pmonsmt PPro Psio 1 22 PrePusPowerEni PPRUCHISTMS 2 4 T connecing Rod Assy PPro S266814 3 33 Filer Coporvent PPRUCAREM 1 5 RwBewnp PPro Psioes 3 3M Sum PPRCHOGNO 20 6 Wn Penoas
61. rque all fasteners to the torque specifications listed on page 30 AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 47 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Chapter 7 Spare Parts Additional Products Ordering Parts Service parts are available through American Mfg Company s worldwide network of distributors or from the original supplier If unsure where to purchase parts contact American Mfg Com pany customer service for the location of an authorized parts retailer in your area Always insist on genuine American Mfg Company replacement parts Use the assembly drawings included with this manual to determine the components and corre sponding part numbers required to service the pump Make sure that the part number on the drawing matches the part number of the pump requiring parts When ordering parts always reference the part number of the pump with the order These num bers can be found stamped on the metal name tag affixed to the power end of every pump By referencing these numbers you can ensure that the components you receive work as intended with your pump Be sure to inquire about any special service tools or complete maintenance kits Also see the Component Parts diagrams on the following pages AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 48 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Ad
62. rt Numbers page 53 AW1118 Drawings starting on page 54 Table 10 AW1118D Component Item and Part Numbers page 58 or Table 11 AW1118B Component ltem and Part Numbers page 59 22 Remove the fluid cylinder this simplifies crankshaft Wa removal on AW1122 model pumps LU 23 Remove the magnetic pipe plug Item 32 to allow all of the oil to drain from the power frame Item 1 24 Remove all of the rear cover cap screws Items 34 25 Remove the back cover Item 15 and the back cover gasket Item 16 from the power frame AW11 Pump Family Operations and Maintenance Manual Revision 2 AMI Page 42 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 26 Remove the end cap of each connecting rod Item 7 4 by unscrewing the two hex nuts that hold each cap to the connecting rod body The cap can then be removed from the body by tapping on the cap screws with a rubber mallet to remove them then tapping on the end cap with the rubber mallet to loosen the cap amp CAUTION Be careful not to damage the threads on the cap screws 27 Slide the two rod bearing halves Item 5 from each connecting rod These parts can sometimes stick to the pins journals on the crankshaft Item 2 take care in the force used to separate them The connecting rods and caps are carefully matched sets and must always be reassembled in the same orientation with their original mate There a
63. rv tos 3 ar cap screw Pion Bearing PPFMCTNS 12 Sr oemp Oynar PPHMCARND 3 28 cap Scew Beaing PPFNC 100604 2 58 Stud CyinderCover PPFMC 1270600 6 x ORing Beaing Perwcazzerio 2 so Barva PPRHCTIOMIS 6 AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 59 of 64 A American Mfg Company Quality Mud Pumps and Parts Figure 12 AW11 Spline Shaft Components Chapter 7 Spare Parts and Additional Products C Q O9 m SS LA LL P Ll Ll al Ll Ll aa A fuf At YY y fj Vy oe pol 3 Q9 QU Y l NN 7 YL Table 12 tem componen Pan ay Pinion Shaft Splined PPFMC 3269385 17 Motor Mounting PPFMC 3269351 1 Plate Oil Seal PPFMC 3269370 zr screw PPFMC mooos4 6 60 Flat Washer PPFMC mo7as6 1 AW11 Pump Family Operations and Maintenance Manual Revision 2 AW11 Spline Shaft Component Item Numbers Items in blue are located on the opposite end of the pinion shaft and are not shown in the drawing above AVI Page 60 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Table 13 Replacement Rubber Item Numbers Replacement Rubbers Component Description 2 3 4 Rubbers AW1122 Pumps LZ Standard Rubbers a Piston Rubber 2 3 4 Neoprene standard production part Alternate rubbers MEE M Piston Rubb
64. s Ensure that the set screws Item 21 that retain the wrist pin Item 6 are in place They may have been re moved for repair or inspection of the wrist pin bushing The set screw must engage the cut out on the wrist pin See page 30 for torque specifications Push the crosshead connecting rod assemblies fully forward in the power frame to pro vide maximum clearance for the crankshaft Ensure that the crosshead assemblies are replaced in the same orientation and in the same cylinder bore that they were originally from The oil cup pocket feeds lubricant to the wrist pin bushing Located on the top of the connecting rod this should be in the up position Install the crankshaft in the power frame Take care not to scratch the bearing surfaces of the crankshaft Inspect the gasket Item 14 that seals the bearing housing and replace it if it is dam aged Reinstall the shims Item 13 and bearing housings As a starting point install the same number of shims that the pump originally had prior to service work this number should have been written down during disassembly When tightening the fas teners retaining the bearing cover use a criss cross pattern when using a torque wrench to tighten them down AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 45 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts 45 Replace the rod bearings Item 5 in the connecting rod and con
65. ual Revision 2 ANI Page 55 of 64 American A Quality Mud Pumps and Parts Figure 10 AW1118D Fluid End Components a 96060 Geom Tn A nT 55 d D ty AT TIR DLL BIBI BI eiaiaiat 1317131214122 LT AN WT SEEN if S I DA I 9 Ss AW11 Pump Family Operations and Maintenance Manual Revision 2 4 ANE V X7 m yyy 63 j LAG ASA ai AAA NA 4 E m Ww WZ E TOT j l8 Mfg Compa ny Chapter 7 Spare Parts and Additional Products CIO o AVI Page 56 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Figure 11 AW1118B Fluid End Components 52 50 63 s DOIS di queue T VAY a SoBe Nag 4 3 en E e amp 8 amp mg S OOO E AW11 Pump Family Operations an d Maintenance Manual Revision NO AM Page 57 of 64 American Mfg Compa ny Chapter 7 Spare Parts and Additional Products Quality Mud Pumps and Parts Table 10 AW1118D Component Item and Part Numbers 1 PoverFrane PPrmosesre 1 30 Screw SefTanpng Prve teran 2 2 Torente _ PPFMC 204 1 ot Pate specion PPRMCSESOSGI 1 3 Pmonsmt PPro Psio 1 22 PrePusPowerEni PPRUCHISTMS 2 4 T connecing Rod Assy PPro S266814 3 33 Filer Coporvent PPRUCAREM 1 5 RwBewnp PPro Psioes 3 3M Sum PPRCHOGNO 20 6 Wn Penoas 3 35 Patek f Perv ne
66. when cold Correct piping system problems Replace defective components Power end oil contaminated Pump was operated with a failed piston cup Replace piston cup and improve monitoring AW11 Pump Family Operations and Maintenance Manual Revision 2 ANI Page 24 of 64 A American Mfg Company Chapter 6 Maintenance Quality Mud Pumps and Parts Chapter 6 Maintenance A WARNING Disconnect the pump trom the driver system and ensure that suction and discharge lines are disconnected or blocked and that there is no pressure at the pump If necessary lockout or tagout the pump and all accessory equipment and or main electrical devices and main switch Failure to do this could cause elec trical shock or injury from moving pump parts or components under high pressure Remove any keys Test the machine to make sure the machine is in fact de energized The only person allowed to remove a Lockout or Tagout device is the person who put it there Be absolutely sure that engine or motor cannot be started Review all of the safety warnings listed in under Safety when Working on the Pump on page 8 Inspection and Preventative Maintenance Routine maintenance is an essential part of any successful pump installation Regular maintenance and inspection will keep your pump operating at peak performance for years of trouble free service American Mfg Company pumps have been carefully engineered to minimize maintenance requirements

Download Pdf Manuals

Related Search

Related Contents

BT ー40    薬食安発 0623第ー号  Dell PowerEdge R820 How to Use  7. BUSCAR REVISTA-E - Universidad de Navarra  Using Dynamic Runtime Testing for Rapid Development of  Instrucciones Ref 709  EOS User`s Guide, Release 2  AE-X3M18JR Installation-Manual HU  Zenoah 3300E User's Manual  

Copyright © All rights reserved. Failed to retrieve file