Bomco F-500 800 1000 Manual

OPERATION AND MAINTENANCE
MANUAL
MODEL : F-500/800/1000 TRIPLEX PUMP

PREFACE
This manual has been prepared according to the drawings of BOMCO rerisededition 2002.This
manual is provided for guidance of those who wish to install, repair, maintain, or adjust the BS
equipment covered herein. This information has been prepared with a basic viewpoint to give
accurate and concise data needed to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators and servicemen who are
familiar with drilling equipment in general. It is neither intended, nor would it be possible in
such limited space, to cover every possible condition which may be encountered. Always use
good, sound mechanical practices and safety precautions.
All specifications are in accordance with Engineering designs and should be adhered to in all
repairs. Operation and maintenance information on equipment other than BS is taken in part
from the various manufacturers’ manuals.
Our company reserves the right to discontinue models at any time, or change specifications or
design of any model without notice and without incurring any obligation.
INDEX
TABLE OF CONTENTS
F-500/800/1000 TRIPLEX PUMP
SECTION TETLE
1 F-500/800/1000 TRIPLEX PUMP OPERATION
& MAINTENANCE MANUAL
2 F-500/800/1000 TRIPLEX PUMP PARTS BOOK
3 KB-45/75 PULSATION DAMPENER PARTS BOOK
4 JA-3 SHEAR RELIEF VALVE PARTS BOOK

1 F-500/800/1000 TRIPLEX PUMP OPERATION
& MAINTENANCE MANUAL
1. TECHNICAL DATA 2.General
dimensions …………………………………… …………………… 6
1.1 Specifications ………………………………………… ……………………. 8
1.2 Parameter Data …………………………………………… …………………… 9
2.INSTALLATION OF NEW PUMP 12

2.1 Setting The Pump ………………………………………………………………… 12
2.2 Land Installations ……………………………………………………………….12
2.3 Permanent Installations …………………………………………………………….. 13
2.4 Installations Of The Drive ………………………………………………………14
2.5 Suction System ………………………………………… …………………… 17
2.6 Power End ……………………………………………………………………………18
2.7 Piston and Liner Cooling System ………………………………………………. 22.
2.8Fluid End Assembly F-500/800/1000 …………………………………………..24
2.9 Accessory Manifold ……………………………………………………………..28
3.LUBRICATION
3.1 Minimum Operating Speeds… …………………………… …………………... 29
3.2 Controlled Flow Splash System ……………………………………………….. .30
3.3 Total Pressure Lubrication System ……………………………………………. 32
3.4 Maintenance of Lubrication System ……………………………………………34
4.MAINTENANCE 36
4.1 Power End ……………………………………………………………………..36
4.2 Roller Bearings …………………………………………………………………..38
4.3 Pinion Shaft Assembly ………………………………………………………….39
4.4 Crankshaft Assembly …………………………………………………………41
4.5InstallingCrankshaft Assembly in Frame ………………………………………...45
4.6Installation of Crosshead Guides ForF-800/1000…………………………… 47
4.7Installation of Crosshead Guide For F-500 ……………………………… 47
4.8 Installation of Crossheads…………………………………………………………..49
4.9 Checking Crosshead Alignment……………………………………………………51
4.10 Fluid End Maintenance…………………………………………………………….52
4.11 Welding and Repairs……………………………………………………………….58
4.12 Repairs to Valve Pot Cover Bore………………………………………………….59
4.13 Operating Maintenance…………………………………… ……………………59
4.14 Troubleshooting …………………………………………… …………………… 63
5.APPROXIMATEWEIGHTOFPUMPASSEMBLIES …………………………………66
6.STORAGE ……………………………………………………………………………….66
7.EXPLAINS FOR ORDER……………………………………………………………….66

1. TECHNICAL DATA
General dimensions
F-500 F-800 F-1000

A 1257.5 1396 1489
B 1452 1628 1673
C 990.5 1129 1173
D 1198.5 1330 1375
E 254 316 340
F 940 1013 1160
G 1130 1216 1363
H 1447 1568 1800
J 2197 2321 2583
L(Dia) 139.7 177.8 196.35
(Keyway) 31.75 15.875 44.45 22.225 50.8 25.4
M 1194 1305 1480.5
N 1543 1657 1818
P 1305 1397 1703
Q 3658 3961 4269
R 389 397 503
S 254 254 320
T 305 330 330
U 628 595 365
V 933 925 696
W 251 273 273
Fig.1
Specification
model F-500 F-800 F-1000
Type Triplex Single Acting Piston Triplex Single Acting Piston Triplex Single Acting Piston
Size,Maximum Bore X Sroke 170X191MM(6.6930”X7.5”) 170x229mm(6.6930”X9”) 170x254mm(6.6930”3x10”)
Speed Rating 165SPM 150SPM 140SPM
House Power Rating 370KW(500HP) 590KW(800HP) 735KW(1000)HP
Type Geae Herringbone Herringbone Herringbone
Gear Rating 4.286:1 4.185:1 4.207:1
Lubrication Pressure & Splash Pressure & Splash Pressure & Splash
Suction Inlet 8”Flang (203mm pprox) 10”Flang (254mm Approx) 12”Flang (305mm Approx)
Discharge Outlet 103mm,35MPa 130mm,35MPa 130mm,35MPa
4”Flang,1500ANSI 5000API 5”Flang,1500ANSI 5000API 5”Flang,1500ANSI 5000API
Pinion Shaft Size 139.7mm(5 1/2”) 177.8mm(7”) 196.9mm(7 3/4”)
Keys 31.75x31.75mm(1 1/4”x1 1/4”) 44.45x44.45mm(1 3/4x1 3/4”) 50.8x50.8mm(2”x2”)
Valve Pots Valve Over Valve API5# Valve Over Valve API6# Valve Over Valve API6#
Valve Cover Screw Type Screw Type Screw Type
Cylinder Head Screw Type Screw Type Screw Type
Liner Lock Screw Type,Metal-Tometal Screw Type,Metal-Tometal Screw Type,Metal-Tometal
Weights 9770kg 14500kg 18790kg
1.3 Performance Data
Performance Data F-500 Pump (Ø170x191)
STROK
HORSEPOWE LINER SIZE (mm) AND PRESSURE RATING( Mpa.kgf/cm2
E
R
PER 170 160 150 140 130 120 110 100
RATING
MINUT 9.3 95 10.5 107 11.9 122 13.7 140 15.9 162 18.6 190 22.2 226 26.8 273
E KW HP VOLUME-LITERS PER SECOND
170 379 515 36.75 32.56 28.61 24.93 21.49 18.31 15.39 12.72
165 368 500 35.67 31.60 27.77 24.19 20.86 17.77 14.93 12.34
150 334 455 32.43 28.73 25.25 21.99 18.96 16.16 13.58 11.22
140 312 424 30.27 26.81 23.56 20.53 17.70 15.08 12.67 10.47
130 290 394 28.11 24.90 21.88 19.06 16.44 14.00 11.77 9.73
120 267 364 25.94 22.98 20.20 17.60 15.17 12.93 10.86 8.98
110 245 333 23.78 21.07 18.52 16.13 13.91 11.85 9.96 8.23
1 0.1262 0.915 0.1683 0.1466 0.1264 0.1077 0.0905 0.0748
NOTE:1.Based on 100% volumentric efficiency and 90% mechanical efficiency
2. Recommended speed and input horsepower for continous service

HORSEPOWE LINER SIZE (mm) AND PRESSURE RATING( Mpa.kgf/cm2)

STROKE
R
PER 170 160 150 140 130 120 110 100
RATING
MINUTE 13.6 139 15.4 157 17.5 178 20.1 205 23.3 237 27.3 278 32.5 331 34.3 350
KW HP VOLUME-LITERS PER SECOND
160 627 853 41.51 36.77 32.32 28.15 24.27 20.8 17.38 14.36
150 588 800 38.92 34.47 30.30 26.39 22.76 19.39 16.29 13.47
140 549 747 36.32 32.17 28.28 24.63 21.24 18.10 15.21 12.57
130 510 693 33.73 29.88 26.26 22.87 19.72 16.81 14.21 11.67
120 471 640 31.13 27.58 24.24 21.11 18.21 15.51 13.03 10.77
110 431 587 28.54 25.28 22.22 19.35 16.69 14.22 11.95 9.87
1 0.2594 0.2298 0.2020 0.1759 0.1517 0.1293 0.1086 0.0898

LINER SIZE (mm) AND PRESSURE RATING( Mpa.kgf/cm2)

STROKE HORSEPOWER
PER RATING 170 160 150 140 130 120 110
MINUTE 16.4 167 18.5 189 21.1 215 24.2 247 28.0 286 32.9 336 34.3 350
kW HP VOLUME-LITERS PER SECOND
150 788 1072 43.24 38.30 33.66 29.33 25.29 21.55 18.10
140 735 1000 40.36 35.75 31.42 27.37 23.60 20.11 16.90
130 683 929 37.47 33.20 29.18 25.42 21.91 18.67 15.69
120 630 857 34.59 30.64 26.93 23.46 20.23 17.24 14.48
110 578 786 31.71 28.09 24.69 21.51 18.54 15.80 13.28
100 525 714 28.83 25.53 22.44 19.55 16.86 14.36 12.07
1 0.2883 0.2553 0.2244 0.1955 0.1686 0.1436 0.1207

2.INSTALLATION OF NEW PUMP
Your F-series pumps has been completely assembled and test operated under pressure before
being shipped to the field. Unless otherwise instructed, the lubrication is drained from the
power end. Before putting the pump into service, the following precautions and operations must
be performed or checked.
In order to prevent personal injury during the performance

of any maintenance or inspection procedures, this equipment
MUST BE SHUT DOWN AND NOT OPERATING, and all
safety devices on prime movers, drives, etc., MUST BE IN
THE SAFE POSITION.
2.1 Setting The Pump
The skid under the pumps manufactured by our company is suitable for most any
type of installation. It should be noted, however, that the box type construction
of the power frame has high resistance to bending but relatively less resistance
against twist. Therefore, the support under the pump must be level and adequate
to support the weight and operating forces exerted by the pump.
2.2 Land Installations
In land installations, a mat of 76mm 305mm boards laid side crosswise to the
pump skids for the entire length, or at a minimum, at the points indicated in
Fig.2,is usually sufficient .The boards should be a few feet wider than the width
of the pump skid runners. Wet or marshy locations may require a more stable
foundation.
Fig.2
2.3 Permanent Installations
On permanent installations such as barge, platform, structural base, or concrete slab, where
pump skids are bolted down, it is essential that the skids be properly shimmed to prevent
possibility of twisting or distorting the power frame. The pump skids must sit solid on all shim
points with bolts loose.
On barge installations, the pump skids are generally bolted down to T-beams running parallel
and in line with the pump skids. Install shims at points shown in Fig, 2 and 3 and observe
caution of proper shimming to prevent twist or distortion.
The shims on all installations should extend the full width of the skid beam flanges and have a
minimum length of 12 (305mm) .
On installations where the power unit or electric motor is mounted integrally with the pump
skids, the preferred installation would be to set the pump package on the T-beam skids and
provide retention blocks rather than bolts to hold it in place. This will allow the pump to “float”
and minimize the transfer of barge deck or platform distortion into the frame.
Fig.3
2.4 Installation Of The Drive
The drive between the mud pumps and the power source, whether V-belts or multiwidth chains,
should be installed with the greatest care to assure maximum operating life with minimum of
unexpected or undesirable shutdowns due to drive failures.
When installing the drive sheave of sprocket, make sure all grease or rust preventative is
removed from the shaft and the bore of the drive. Remove all burrs or rough spots from the
shaft, key, and keyway .Fit key to the keyways in both the shaft and drive and install key into
shaft keyway.
Coat pinion shaft with a light coating of anti-seize compound or light oil and install the drive
sheave or sprocket hub. Tighten hub bolts as indicated below:
When a wrench or length of pipe is used to increase leverage in tightening draw-up bolts, it is
imperative to adhere to the wrench torque values given in the chart below. This adherence is
important, because in mounting the hub, the tightening force on the bolts is multiplied many
times by the wedging action of the tapered surface. This action compresses the hub for a snug
fit on the shaft. If the bolt-tightening forces are extreme, bursting pressure is created in the hub
of the mounted pulley, this pressure may cause the pulley to crack. The hub bolts should
always be tightened alternately and progressively.
QD Wrench Wrench Wrench pull
Pump Type Hub Torque Length N
* N.m mm
F-500 N 406 760 534
F-800 P 610 760 800
F-1000 W 813 900 900

*Refer To Eaton Transmission Products Catalog For QD Busing Size
2.4.1 V-Belt Drives
a. Check sheave groove condition.

Before installing the v-belts, check sheave grooves for wear. worn or rounded grooves will
destroy V-belts rapidly. The side walls must be straight. Sheave grooves must be free of dirt,
rust or other extrusions which could damage the V-belts.
b. Check sheave alignment.

The final alignment of the V-belt sheaves should be checked after the V-belts have been
installed and adjusted to their operating tension. If the sides of the sheaves are of equal
distance from the centerline l of the groove, check alignment by stretching TWO strings (fish
line or piano wire preferred )along one side of the two sheaves, one above and one below the
centerline, and moving one of the sheaves until the strings touch four points on the side of
the sheave rims. This will determine that the centerline of the drives are parallel and the
faces of the sheaves are square.
c. Adjust V-belt for proper tension

Adjust the belt tension by moving the sheaves apart until all of the sag has just been
eliminated from the tight side of the belt and some of the belts on the slack side. Then
increase the centers approximately 13mm(1/2 )for each 2540mm(100 )
Center distance. Example: On 3180mm(150 )center, move pump and additional
19.5mm(3/4 ).
DO NOT OBTAIN BELT TENSION BY PICKING UP END OF PUMP AND

ALLOWING BELTS TO TIGHTEN UNDER WEIGHT OF PUMP AS END IS BEING
LOWERED TO THE GROUND.
2.4.2 Chain Drives
a. Installation
Proper installation and maintenance of the sprocket and chain drives are essential if good
service life is to be obtained. since many factors, such as chain width, center distances,
speeds, and loads must be considered when determining the allowable tolerance for sprocket
alignment, no good “rule of thumb” can be applied. The chain alignment must simply be
held as nearly perfect as possible. A more precise alignment can be made by stretching two
steel wires (piano wire)along one face of the two sprockets, one above and one below the
centerline, and moving one of the sprockets until the wires touch at four points. This will
determine that the centerlines of the drives are parallel and the faces of the sprockets are
square.
b. Drive chain lubrication

The pump drive chain lubrication system on the majority of BS pumps is an independent
system having its own oil pump, reservoir, and drive. Fill chain case to the indicated level
with a non-detergent oil as follows:
Ambient temperature above 32 F(0 C) SAE-30
Ambient temperature below 32 F(0 C) SAE-20
For temperatures below 0 F, consult a reputable lubrication dealer for recommendations.
REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and

additional specifications. If any discrepancy exists between the recommendations in this
manual and the General Lubrication Bulletin, those in the Lubrication Bulletin will take
precedence.
Since this is an independent system, it will require the same maintenance or service attention
employed on any other piece of machinery, including:
- Daily check of oil level.
- Daily check on condition of oil.
- Frequent check on oil pressure. (5-15psi) (0.352-1.06kg .cm2).
- Volume of oil being applied to chain.
- Condition of nozzles in spray tube.
- Conditon of oil pump drive (V-belts or chain)
NOTE: Oil pressure may be adjusted with the pressure relief adjusting screw on the rear
of the pump housing. Pressure drops may also indicate suction and discharge filter
screens need cleaning.
2.5 Suction System Requirements
Individual installation conditions will dictate the design of the suction system. The suction of
the BS F-series pumps must have a positive head (pressure)for satisfactory performance. The
optimum suction manifold pressure is 20-30 psi (0.14 – 0. 21Mpa) for maximum volumetric
efficiency and expendable parts life. This head pressure is best supplied by a 5 x 6 centrifugal
pump with 40h.p 1150 rpm electric motor. This type of drive requires a device to automatically
start and stop the centrifugal pump motor simultaneously with the triplex pump. On DC electric
powered a signal can usually be supplied from the DC control panel to energize a magnetic
starter when the mud pump clutch air line will provide a set of contacts for energizing the
magnetic starter when clutch is engaged.
The charging pump can also be belt driven from the triplex pinion shaft charging type of drive
is not as efficient at slow speeds with viscous fluids.
Under some conditions the BS F-Series pumps may be operated without a charging pump,
provided the fluid level in mud pits is higher than the top of the liners, fluid being pumped is
low viscosity and suction line must be short, straight and of at least the same diameter as
suction manifold inlet.
The suction lines should be piped with valve arrangements so the charging pump can be
by-passed so operation can be continued in event of charging pump failure or for maintenance.
Operation without a charging pump can be improved by replacing the suction valve spring with
a weaker spring.
Suction desurgers are a very effective aid for complete filling of the liners and dampening
pulsations in the suction line which results in a smoother flow in the discharge line.
CAUTION
Do not pipe the return line from the shear relief valve back into the suction system as a relief
valve operation will cause a sudden pressure rise in the system vastly greater than the system
pressure ratings, resulting in damage to manifold, suction desurger and centrifugal pump.
2..6 Power End
Your pump has been completely assembled and test operated before being shipped to the
field. Unless otherwise instructed, the lubrication is drained from the power eng, and the
expendables are removed from the fluid end for storage protection. Before operating the
pump, the following must be performed or checked.
2.6.1 Power End Lubrication
Before installing lubricant, open inspection door in cover and check oil reservoir for possible
accumulation of condensation, etc, and drain and flush by removing the pipe plugs on each
side of the pump. Refer Item 2.Fig.7.
Add the proper type and quantity of lubrication in the power end. Refer to lubrication plate
on pump frame for type and quantity required.
Recheck oil level after pump has operated for a period of 15 minutes. Shut pump down and
allow approximately five minutes for the oil level to equalize, Check at oil level gauge, Item
1, Fig 7.It is usually necessary for a few more gallons of oil to be added due to a certain
amount being retained in the crosshead area and frame cavities.
2.6.2 Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals. for F-500
pump.
With reference to Figure 4A, remove the diaphragm stuffing box and plate(1)and rotate
pump so that crosshead is at the front of the stroke, Thoroughly clean the front of the
crosshead and the face of the crosshead extension rod. Insert alignment boss on crosshead
extension rod into the crosshead bore and tighten the retainer bolts (2)to the following torque,
67.5-81 N·m(50-60ft· lbs)Safety wire bolt heads.
Fig.4A
Thoroughly clean face of crosshead guide (3)and diaphragm stuffing box (1).Install O-ring
seal (4).fit connection (5)on diaphragm stuffing box (1),Install diaphragm stuffing box and
tighten cap screws to the following torque:
16-19 N·m (12 – 14 ft·lbs)
Fit oil pipe (6)

The diaphragm stuffing box packing assembly consists of two double lip Oil Seal(7)a Oil
Seal ring (8) an O-ring (9) a lock spring (10), and a O-ring (1) Install the assembly as
follows:
a. Remove pressure spring (7a)from double lip oil seal (7)and place seal in the inner (power
end )position on the crosshead extension rod, with lip toward power end, Replace the
pressure spring in the seal lip and slide the seal into position in the stuffing box.
b. Insert the Oil Seal ring (8)and O-ring (11)over rod and slide it into stuffing box bore.
c. Insert the O-ring (9) in groove in stuffing box bore.
d. Install the lock spring (10).
Note: CAUTION must be exercised to assure the pressure spring (7a)does not slip out of the
groove in the oil seal lip, as severe scoring of the crosshead extension rod can occur .Coat
extension rod with a light oil to facilitate installation of the packing assembly.
2.6.3 Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals For F-800,
F-1000.
Fig.4B
With reference to Fig. 4B ,remove the diaphragm stuffing box and plate (1)and rotate pump
so that crosshead is at the front of the stroke. Thoroughly clean the front of the crosshead and
the face of the crosshead extension rod. Insert alignment boss on crosshead extension rod
into the crosshead bore and tighten the retainer bolts (2) to the following torque. Safety wire
bolt heads.
F-800 110 135 N· m (80 100ft·lbs)
F-1000 475 500 N·m (350 370ft·lbs)
Thoroughly clean face of power frame and diaphragm stuffing box plate at position “A”.
Install gasket (3)and cap screws (10). Tighten cap screws as follows:
F-800 16 24 N·m (12 18 ft·lbs)
F-1000 16 24 N·m (12 18 ft·lbs)
Clean bore and face of diaphragm stuffing box plate .Clean OD and flange of diaphragm
stuffing box. Coat OD of diaphragm stuffing box with light oil and install O-ring seal
(4).Inset diaphragm stuffing box in plate bore and tighten cap screws to the following torque:
F-800 16 24 N·m (12 18 ft·lbs)

F-1000 16 24 N·m (12 18 ft·lbs)
The diaphragm stuffing box packing assembly consists of two double lip oil seal (6),a oil
seal ring (7), a O-ring (12) O-ring (8)and a lock spring (9). Install the assembly as follows:
a. Remove left pressure spring (5) from double lip oil seal (6)and place seal in the inner (power
end)position on the crosshead extension rod, with lip toward power end. Replace the pressure
spring in the seal lip and slide the seal into position in the stuffing box.
SEE NOTE BELOW
b. Install the O-ring (12) into Oil Seal ring (7).Insert O-ring (12) and oil seal ring (7) over rod and
slide it into stuffing box bore.
c. Install the O-ring (8)in groove in stuffing box bore.
d. Remove right pressure spring(5)from double lip oil seal(6)and place seal in the outer position
on the crosshead extension rod with main lip toward power end. Replace the pressure spring in
the seal lip and slide the seal into position in the stuffing box.
SEE NOTE BELOW

CAUTION: The double lip seal can be used in the inner, or power end, power end, position to
replace the single lip seal, but DO NOT use the single lip seal in the outer position.
e. Install the lock spring (9)
NOTE:CAUTON must be taken to assure the pressure spring (5)does not slip out of the groove in
the oil seal lip, as severe scoring of the crosshead extension rod can occur. Coat extension
rod with a light oil to facilitate installation of the packing assembly.
2.7 Piston And Liner Cooling System
Proper attention must be paid at all times to assure adequate cooling fluid is being applied to
the piston and liner assembly. Stoppage of the cooling fluid will result in almost instant
failure of the piston rubbers and possibly extensive damage to the liner bore.
Stationary spray type have been used on BS F-series pumps Ref.

Fig 5.It consists of a fixture (1), a pipe (2)and a spray nozzle (3),which applies cooling
fluid in the form of a spray to the piston and liner area. Adjust cooling water supply to the
manifold so that a spray approximately 305mm long is being discharged from each spray
nozzle. Inspect spray nozzle operation very often making sure the nozzle is pointed directly
at the piston.
Cooling fluid be transfused from pump (Item 3 Fig .6) and Water tank (Item 5. Fig. 6 ) to
the manifold on the frame. Adjust regulating valve (Item 4 Fig .6) to apply as much water as
possible to the liners without splashing back on the crosshead extension rods and diaphragm
stuffing box plate. 40L(10- gallons) per minute per liner is the preferred flow rate. If water is
allowed to splash on the crosshead extension rods, some of the water will work back into the
power end to contaminate the lubrication oil.
Fig.5
Fig.6
The cooling fluid is returned from the crosshead extension rod compartment to the setting
chamber, and as the fluid overflows through the filter screen between the two sections of the
tank, the solids are allowed to settle out. The filter screen will catch much of the foreign
material floating in the fluid. With reference to Fig .7
Check condition of the cooling fluid at frequent intervals and CLEAN and FLUSH reservoir as
required. Contaminated fluid will cause premature liner and piston wear from abrasion or
stoppage of the spray nozzle or spray tube.
Fig.7
2.8 Fluid End Assembly
2.8.1 Valves and seats
Remove all three discharge valve pot covers (1), and the three cylinder heads (2)and plugs(10),
and thoroughly clean all machined surfaces in the fluid end with a good cleaning solvent.
Make sure all valve seat bores are VERY CLEAN AND DRY(free of dirt, grease ,anti-rust
compound ,etc)and remove all burrs or nicks with a fine emery cloth ,using circular motion
around seat surfaces.
THOROUGHLY CLEAN AND DRY the valve seats and install suction and discharge valve
seats into the valve pot bores. Drive seats firmly into place with a bar and hammer. Install
valves and springs and the other parts.
2.8.2 Install fluid baffle (11) fig 8.8A on end of crosshead extension rod.
F-500, F-800, F-1000 ASSEMBLY OF FLUID END PARTS
Fig.8
A cross-section through the fluid end for F-500, F-800,and F-1000 is shown in Fig, 8. With
reference to Fig 8, clean and assemble the fluid end parts in the following manner:
Liners
Inspect liner bore again to make sure it is clean and free of foreign particles to assure metal
contact between the liner and fluid end. Foreign particles can cause the liner to make up in a
“cocked ”position resulting in premature wear on liners and pistons.
Apply a light coat of grease or oil to the liner bore of the fluid end. A heavy coat of grease will
cause a hydrostatic lock which will prevent the liner from seating in its proper position. Push
liner through liner bore until it seats metal to metal against the fluid end shoulder.
2.8.3 Piston Rod
Clean piston and piston rod, making sure they are free of nicks and burrs. Install “O ” ring seal
(20) in grove in piston head .Slide piston head on rod while observing that “O” ring does not
fall out of groove. Tighten piston rod nut(21) to the following torque.
F-500 500 N m (368 ft lbs)

F-800/1000 1625-2165 N m (1200-1600ft lbs)
Coat liner I.D. and piston O.D.with grease. Check ends of piston rod and extension rod to be
sure they are clean and free of burrs. Insert piston rod through liner holding piston rod centered
at the rear of the liner. Drive the piston into the liner with a driving tool or a piece of hardwood
and sledge hammer. Use caution as the piston rod approaches the crosshead extension rod that
the dowel on the end of the piston rod is not damaged. The piston rod must be supported and
the dowel guided into the pilot bore.
2.8.4 Piston Rod Clamps
The piston rod clamps are machined as one piece and then cut in half, the two pieces are
stenciled with matching numbers on each half and have a chain link connecting them together.
the two pieces with the same matching numbers should always be kept together as a set.
Tighten cap screws to the following torque values.
F-500 135 N m (100 ft lbs)
F-800 135 N m (100 ft lbs)
F-1000 215 N m (160 ft lbs)
When rods and rod clamps are new a gap in excess of 5.5mm could be present between the two
halves of the clamp. This is satisfactory provided the faces of the rods are seating metal to metal.
As wear occurs, the halves will pull closer together. Clamping action will be lost when a gap no
longer exist. At this time clamps must be replaced.
2.8.5 Liner Cage and Lower Valve Guide
Install rear liner seal (5)and push into position against liner shoulder. Ref.
Fig .8. Slide liner cage (6)into fluid end, align one hole in the cage with lower valve pot bore.
Set lower valve guide (8) over valve stem through lower hole in cage with the wings on the
guide turned crosswise to the pump. Press down on the guide, compressing the valve spring (7)
until the guide can be rotated 1/4 turn and seat into place underneath the cage. Insert the lower
valve guide locking clip (9)through the pad eyes on the lower valve guide and rotate clip to the
right to lock the valve guide tight against the OD of the liner cage. It may sometimes be
necessary to put more of less bend in the center of the clip to make it retain the guide tightly
while the clip handle snaps into position on the right hand side.
2.8.6 Cylinder Head
Insert the outer seal (5)in the fluid end bore against the liner cage. Slide the cylinder head
plug(10)into fluid end. Apply a liberal coat of grease to both mating thread surfaces of the
cylinder head (2)Screw cylinder head in and tighten with wrench furnished with pump and
sledge hammer.
Fluid leakage through the weep hole will indicate a defective seal or loose cylinder head. DO
NOT plug weep holes as this can result in severe damage to cylinder head threads, thread rings,
etc, in event of a liner seal failure.
2.8.7 Discharge Valve Pot Covers
Install discharge valve pot gasket (3) into bore, and after liberal application of grease or tool
joint compound to the gasket and thread area, tighten the discharge valve pot covers into place,
using a sledge hammer and bar.
2.8.8 Discharge Manifold all Models
A flange (4" for F-500,5" for F-800/1000) connection is provided on the discharge manifold.
Remove flange and protect gasket area before welding(customer' s option ) to the discharge
piping .Tighten discharge flange connection bolts to 1625-2165 N.m
(1200-1600ft.lbs .)torque. To insure uniform make-up of the ring joint connection, tighten
flange bolt nuts in a criss cross order. If a blind flange is installed on the opposite end of the
discharge manifold, check flange bolts and tighten to same specification as noted above.
2.8.9 Suction Flange
The suction flange has a standard thread connection (8" NPT for F-500, 10" NPT for F-800,
12" NPT for F-1000)and is custom made to match the companion flange on the pump
suction manifold. The connection is sealed off by an O-ring seal.
Note: Thoroughly clean O-ring groove and face of flanges before making up connection. Tighten
flange bolts to 490 665 N·m.
2.9 Accessory Manifold
Fig.9
An accessory manifold Fig .9.is available for installation on the discharge manifold opposite the
discharge end, The manifold will accommodate a BS pulsation dampener (1)(KB-45 for
F-500/800, KB-75 for F-1000 and others ) and provides a 3"NPT and a ZG1-1/2"side outlet
connections for such items as a shear relief valve (3)and a pressure gauge (2)when manifold is
used, install and maintain as follows:
Thoroughly clean ring joint groove, install ring (4)and tighten the flange bolts (5)to 1625N.m.
torque. To assure uniform make-up of the ring joint connection, tighten the nuts in a cross -
cross order.
The shear relief valve (3) is installed on the discharge manifold for the purpose of protecting the
pump from excessively high pressure overloads. The relief valve must be installed so that is
will be directly exposed to the mud. DO NOT PUT ANY TYPE OF SHUT OFF VALAE
between the relief valve and the manifold. Pipe the discharge side of the relief valve directly
into the mud pit with as few turns in the line as possible. IT IS NOT RECOMMENDED for
the discharge side of the vale to be piped into the suction line of the pump.
The relief valve setting should be just above the maximum pressure rating of the particular liner
size being used.CHANGE SETTINGS with each liner size change .DO NOT USE ALLEN
WRENCHES, WELDING RODS. or material other than that called for by the manufacturer
of the relief valve, as this will affect the rating of the relief valve.
The mounting for KB-75 and KB-45 pulsation dampener (1)is a flange with R-39 ring gasket.
Before installing dampener, thoroughly clean ring groove and ring, and after setting dampener
into place, tighten the nut (8)to 1020N.M torque. to insure uniform make-up, tighten nuts in a
cross-cross order.
Precharge dampener before starting up pump. Precharge pressure should not be more than 2/3
of the pump discharge pressure, or a maximum of 4.5Mpa.
CAUTION: Use only compressed nitrogen or air. Do not charge with oxygen.
3. LUBRICATION
Proper lubrication of the moving parts in any piece of machinery is the most important single
factor affecting its ultimate life. To obtain maximum trouble-free service life from the power
end of the BS pump, it is necessary to perform routine maintenance care and inspections to
insure the proper amount of CLEAN lubricant is being provided.
The F-Series pumps utilize the controlled flow oil bath splash and pressure system to lubricate
the entire power end. The type of pressure system provided in each individual pump will govern
the minimum SPM at which the pump can be operated, i.e. pumps which have pressure
lubrication only to the main and pinion bearings, have a minimum rated speed of 40 SPM.
Pumps in which pressure lubrication is provided to the main, pinion, and crosshead bearings
and crosshead compartments may be operated at a minimum speed of 25 SPM. Provided there
is a minimum of 0.035Mpa (5PSI)oil pressure.
3.1 Minimum Operating Speeds
F-series pump have the total pressure lubrication system, and which can be operated at 25
SPM (at pressure of 0.035 MPa)
CAUTION: The pressure lubricating system can be provided with an externally mounted oil
pump driven through V-belts or an internally mounted oil pump driven from the main gear.
When an internally mounted oil pump is used, the direction of rotation of the pinion shaft must
be as shown in Fig. 10.
Fig.10
3.2 Controlled Flow Splash System
The controlled flow splash lubrication system is the same for all F-Series pumps, regardless of
the type of oil pump drive provided for the pressure system In the controlled flow splash system,
the main gear picks oil up from the reservoir, and when the teeth mesh with the pinion, the oil is
displaced into various troughs and compartments in the frame With reference to Figure 12, the
oil thrown into trough (7) is directed through the oil tube (8)to the two pinion bearings.
Oil passage from the of the crosshead guide compartment to the crosshead bearing is shown in
Figure 11,Oil accumulates in the compartment over the crossheads. The oil runs through the
nipple (1) into the crosshead retainer to the oil passages (5)and on to the crosshead pin bearing.
As noted, the duplicate set of passageways(5)in the crosshead pin permits the crosshead pins to
be rotated without having to give attention to hole alignment . This permits the installation of
crosshead pins from either direction.
For F-500 pump. Oil passage from the top of the crosshead guide compartment to the crosshead
bearing is shown in Fig. 11A .Oil accumulates in the compartment over the crossheads. The oil
runs through the oil passage, (1) (2)and crosshead pins oil passage (3),and on to the crosshead
pin bearing. As noted, the duplicate set of passageways (3)in the crosshead pin permits the
crosshead pins to be rotated without having to give attention to hole alignment. This permits the
installation of crosshead pins from either direction.
Fig.11
Fig.11A
3.3 Total Pressure Lubrication System
The total pressure lubrication system, incorporating the oil pump for the F-series pumps, is
shown in Figure 12.
In this system, filtered oil is supplied to the pump through the suction filter (1)and is
discharged from the pump into the manifold block (2). Oil is distributed from the manifold
block to the pinion shaft bearing oil line (3)and spray nozzle (3A),and to the main bearing oil
line (4)and the crosshead compartment manifold block (4A)located above the crosshead
compartment. The crosshead compartment manifold block (4A) distributes oil to the crosshead,
crosshead bearings, and extension rods.
A pressure gauge (5)is mounted on the back wall of the frame to show oil pressure being
maintained in the manifold block. The oil pressure will, of course, very with the speed of the
main pump, however if a sudden pressure drop or increase occurs, refer to the section on
maintenance of lubrication system for possible cause.
A pressure relief valve (6) is mounted to the manifold block (2)to keep excess pressure from
damaging oil pump and drive. The relief valve is preset at o. 27Mpa (40 PSI) and must not be
tampered wit.
When installing the internally mounted oil pump (9 Fig .12), position pump so that the back
face of the drive gear is flush and parallel with the edge of the main gear, and gear teeth have
0.60 0.90mm backlash .
Fig.12
A typical layout for the pinion shaft driven oil pump is shown in Fig. 13.The oil pump (1) is
piped into the oil system through the suction and pressure connections on the bottom inside wall
of the power frame.
Fig.13
Ref. Fig .13. Adjust the V-belt drive (2)to a point where the two halves of the belt can almost be
“pinched” together between the thumb and fingers at the center of the drive. Over tightening
can cause premature failure of the pump.
To prevent possible injury, always install guard (3 Fig.13)over V-belts before putting pump into
service.
3.4 Maintenance Of The Lubrication
Adequate lubrication of the moving parts is, as stated, the most important single factor affecting
the ultimate service life of the pump, CARE AND MAINTENANCE of the system is the sole
responsibility of the operator or crew to which it has been assigned, and the extent to which this
is applied will determine the amount of trouble – free service life that will be obtained.
The lubricant recommendations shown below, on the name plate on the side of the pump, are
the result of extensive field tests. Substitutions should be made only in extreme emergencies.
Lubrication specifications:
Use extreme pressure non-corrosive, anti- foaming gear lubricant as follows:
Temperatures +30° F +155° F (-1°C +68°C) AGMA NO. 6#EP

Temperatures + 0° F + 80° F (-18°C +27°C) AGMA NO. 4#EP
Temperatures -20° F +40° F (-29°C + 4°C) 1#EP
Oil reservoir capacity:

F-500 246 liters (65 U.S . Gal )
F-800 246 liters (65 U.S . Gal )
F-1000 284 liters (75 U.S . Gal )
ONCE EACH TOUR, check and maintain oil level at the EULL mark on the bayonet gauge.
PUMP MUST BE SHUT DOWN and allowed to stand idle for approximately five minutes to
allow oil level to equalize.
ONCE EACH SIX MONTHS, or more often if oil becomes contaminated with abrasive
particles or corrosive compounds, drain and flush the oil reservoir new lubricant. Oil drains are
located on either side of the pump frame.
During the flushing procedure, thoroughly clean the oil troughs and the compartment in top of
the crosshead guide. Also clean or replace the filter element in the air breather cap and clean
suction screen . Remove covers from settling chamber and purge out contaminants before
adding new oil .
Routine inspection on condition of oil should be made as condensation of moisture in the air,
intrusion of mud, water or dirt, can necessitate a more frequent oil change.
A settling chamber is located in the forward area of the power end floor, Contamination in the
oil splashed into this area is allowed to settle out and should be drained out of the pump through
the clean out covers located on the frame wall underneath the crosshead inspection doors.
Once each month, remove clean out covers on both sides of pump to drain contaminated oil
from setting chamber. Approximately 15-gallons of oil be lost; replenish the main reservoir to
compensate for the amount drained out.
Once each week, remove one of the lower 1/2" capscrews that secure the clean out cover to the
frame to drain off water condensate.
ONCE EACH TOUR, check oil level in main reservoir. Maintain at full mark on dipstick to
the manifold block. If loss of pressure occurs, check for:
- Clogged suction screen

- Low oil level
- Slipping V-belt drive
- Broken or loose connections
- Damaged or worn oil pump
- Defective Relief valve
For an abnormal increase in oil pressure, check for:

- Plugged oil lines
- Contamination causing oil to be viscous
- Relief valve inoperative
- Defective gauge
- Other conditions
4.MANTENANCE
4.1 Power End
Routine inspection of the power end is the most important form of preventive maintenance
and will result in considerable savings by detecting any major trouble that might be
developing and allowing the necessary repairs to be made on a planned or normal rig-down
time.
4.1.1 Check tightness of the main bearing bolts. Bolts must be tightened to the following torque:
F-500 4065 N·m (3000ft·lbs)

F-800 8620 N·m (6360ft·lbs)
F-1000 11920 N·m (8800ft·lbs)
4.1.2 Safety wires-
Check safety wires on all bolts including the main bearing hold-down bolts and eccentric
bearing retainer bolts, Replace any broken wires after retightening the bolts, Refer to
crankshaft assembly section for bolt requirements .
4.1.3 Oil lines-
Check all oil lines to insure they are intact and free of obstructions. Check oil pump suction
hose for damage or flat areas.
4.1.4 Suction filter-
Check condition of suction filter. Clean and replace as required.

4.1.5 Main bearing cover-
Remove the main bearing cover and check tightness of main bearing retainer blots, condition
of the bearing rollers, etc. Clean and remove any sludge or foreign substance that might have
accumulated at the bottom of the bearing area.
4.1.6 Main gear and pinion teeth-
Inspect the condition of the main gear teeth and pinion gear teeth for any indications of
abnormal wear. During the initial break-in period there will be some pitting on the face of the
gear teeth. This is referred to as initial pitting and is not harmful to the life of the gear.
However, if routine inspection indicates the degree of pitting continues to increase,
immediately contact the pump manufacturer for a more thorough inspection of the gear.
4.1.7 Crosshead pin bolts and crosshead guides-
Remove cover and check condition of the crosshead pin bolts and safety wires. (Center
crosshead pin bolts can be reached by removing back cover and placing eccentric on outer
top dead center). Tighten crosshead bolts (Item 4 Fig .18) to the following torque:
F-500 120-135 N.m (90-100ft.lbs)
F-800 190-205 N.m (140-150ft.lbs)
F-1000 225-240 N.m (165-175ft.lbs)
DO NOT EXCEED THESE VALUES. USE TORQUE WRENCH
If the crosshead or guide shows abnormal wear or scoring , replace immediately as the metal
particles can cause damage to the bearings, etc; Excess wear can also cause rapid wear to the
piston and liner.
4.1.8 Oil and oil reservoir-

Check condition of the oil and cleanliness of the oil reservoir. Service oil system as described in
the Lubrication Section of this manual.
4.2 Roller Bearings
Although the basic construction of the various sizes of F–series pumps varies somewhat, they
all have one very important detail in common roller bearings. A roller bearing is a precisely
built machine within itself; therefore, careful handling is required in order to obtain the long
service life and high load carrying characteristics associated with anti-frication bearings.
The main bearings are self-aligning spherical roller bearings. The pinion shaft is mounted on
straight roller bearings. The eccentric bearings are straight roller with thrust plates on each
side to keep the eccentric straps in line, and the crosshead pin bearings are straight needle
roller bearings.
None of the bearings require special adjustments.
All inner and outer races are assembled by means of very accurate fits. This accuracy is
necessary ;therefore, if the bearings are to be used again ,the inner and outer races and the
roller assemblies of each bearing must be kept together, and reinstalled exactly as they came
off.
It is always necessary to completely replace any roller bearing that fails, even though only one
part of the bearing shows damage. Since the running clearances of these bearings are
extremely small, excessive clearances, worn or grooved raceways ,and any pitting or flaking
of the parts is indicative of failure and the entire bearing should be changed as soon as
possible.
All roller bearings are assembled to their shafts by means of shrink fits. (Ref. bearing fit data
under each shaft assembly.) Damaged or worn bearings and raceways can be removed by
driving them off the shaft with a bar and hammer. They can be cut off the shaft with a burning
torch, but care must be taken not to burn into the shaft. Bearings should always be heated in an
oil bath ,the temperature of which should not exceed 149 .(300 F). Be certain that both
the oil and the container are very clean. If the oil container is in direct contact with the fire,
place a rack into the container so that the bearings will not rest on the the bottom. Do not leave
the bearings in the oil bath longer than three minutes.
Do not heat the bearings with a torch unless it is the only possible means available. When it is
necessary to use a torch, it should be used only by an experienced welder or mechanic .Hold
the torch at least 150mm (6 inches ) away from the bearing and keep the torch moving at all
times. Heat the bearing only until it is hot to the touch. Use a Tempil stick . DO NOT
OVERHEAT THE BEARING. Overheating draws the temper of the metal and makes the
bearing soft.
Once the heated bearing is in place on the shaft, hold it in place until it cools. NEVER USE
WATER OR ANY OTHER LIQUID TO COOL A HOT BEARING. Rapid cooling will
cause the surfaces of the races and rollers to “check” or crack and the bearing will fail
immediately.
Never strike a roller bearing with a steel hammer. If the bearing must be driven into position,
use wood or a soft hammer and strike lightly.
Always lubricate the shaft or housing before installing the bearing. Clean white lead, or an
anti-seize compound, is the best lubricant for this purpose.
Do not remove a new bearing from the box or wrapping until it is to be installed, Protect it
from dirt and other foreign matter at all times. If a bearing must be cleaned, use clean kerosene
or other solvent.
4.3 Pinion Shaft Assembly
Fig.14
GHART 1
mm
Description Position F-500 F-800 F-1000
Inner Race.. to Shaft A T 0.030 T0.081 T0.035 T0.085 T0.050 T0.109
Outer Race.. to Bore B L0.068 T0.018 L0.095 L0.010 L0.0105 L0.015
Carrier to frame Bore C L0.203 L0.076 L0.203 L0.076 L0.203 L0.076
Inches
Description Position BS F-500 BS F-800 BS F-1000

Inner Race.. to Shaft A T 0.0012 T0.0032 T0.0014 T0.0033 T0.002 T0.0041
Outer Race. .to Bore B L0.0015 T0.0005 L0.0037 L0.0004 L0.0041 L0.0006
Carrier to frame Bore C L0.008 L0.003 L0.008 L0.003 L0.008 L0.003
The pinion is an integral part of the shaft leaving only the installation of the bearings and oil
seal Spacer to complete the assembly.
The running clearances of the bearings are predetermined by their precision fit to the shaft
and the bearing carrier. When performing maintenance or overhaul, make sure the fits
show in chart I are obtained.
When installing the pinion shaft assembly in the pump observe the following precautions:
a. Insure pinion bearing carrier gasket (1) and oil seal carrier gasket (2) are in place and in
good condition.
b. When installing the pinion bearing carrier (3) and the oil seal carrier MAKE SURE THE
CARRIERS ARE INSTALLED WITH DRAIN HOLES AT THE TOP to correctly position
oil troughs and align drain holes.
c. Remove burrs, dents or gouges from the OD of the oil seal spacer (5) before sliding oil seal
carrier (4) into place. Exercise care when sliding lip of seal over end of shaft to prevent it
from being damaged by the sharp edge of the keyway . Also pay particular attention to
insure oil seal lip IS NOT TURNED UNDER by edge of spacer when sliding seal onto the
spacer.
d. Tighten pinion bearing carrier bolts (6) to the approximate torque shown below.
F-500 135 170 N·m (100-125ft · lbs)
F-800 135 170 N·m (100-125 ft · lbs)
F-1000 190 225 N·m (140-165 ft · lbs)
e. Check condition of the pinion bearing inner and outer race and rollers. If there is any
indication of galling, flaking or grooving , or if diametral clearance exceeds 0.20 0.25mm,
it is recommended the entire bearing be replaced.
4.4 Crankshaft Assembly (Fig .15)
The crankshaft assembly consists of the crankshaft, eccentric ring gear, eccentric strap with
bearings, and the main bearings.
The running clearances of the bearings are predetermined by their precision fit to the shaft
and their respective bores, When performing any maintenance or overhaul, make sure the
fit . shown in chart II are obtained.
Fig.15
CHART II
mm
Inner Race.to Shaft A T0.050 T0.109 T0.055 T0.114 T0.060 T0.121
Outer Race.to Bore B L0.080 0 L0.090 0 L0.095 0
Inner Race.to Shaft C T0.076 T0.172 T0.127 T0.228 T0.127 T0.228
Outer Race.to Bore D T0.100 0 T0.100 0 T0.100 L0.025
Gear to Flange E T0.025 T0.127 T0.025 T0.127 T0.025 T0.127
Carrier to Frame Bore F L0.050 T0.025 L0.051 T0.051 L0.051 T0.051
Outer Race.to Bore G 0 T0.050 T0.025 T0.085 T0.012 T0.079
Inner Race.to Pin H 0 T0.045 T0.025 T0.075 T0.025 T0.075
Inches
Inner Race.to Shaft A T0.0020 T0.0043 T0.0022 T0.0045 T0.0024 T0.0048
Outer Race.to Bore B L0.0031 0 L0.0035 0 L0.0037 0
Inner Race.to Shaft C T0.0030 T0.0068 T0.005 T0.0090 T0.005 T0.009
Outer Race.to Bore D T0.0039 0 T0.0039 0 T0.0039 L0.0010
Gear to Flange E T0.001 T0.005 T0.001 T0.005 T0.001 T0.005
Carrier to Frame Bore F L0.0020 T0.001 L0.002 T0.002 L0.002 T0.002
Outer Race.to Bore G 0 T0.002 T0.0010 T0.0034 T0.0005 T0.0031
Inner Race.to Pin H 0 T0.0018 T0.0010 T0.0030 T0.001 T0.0030
Assemble the crankshaft in the following manner:(Refer to Fig.15)
a. Mount gear on flange
Thoroughly clean mating faces of ring gear and flange and bolt flange into position .Tighten
flange bolts (2) to the following torque:
F-500 400 N·m (295ft·lbs)
F-800 1055 N·m (778 ft·lbs)
F-1000 1055 N·m (778 ft·lbs)
Set crankshaft on a set of rollers (at main bearing position) and check runout on face of gear
with a dial indicator. If total indicator runout exceeds 0.15mm, remove gear and gear and
determine cause of misalignment.
Note: If runout on face of gear is checked while crankshaft is mounted in the pump frame,
the running clearance in main bearings will require that a simultaneous set of dial
indicator readings be taken at the end of the shaft and the face of the gear; the actual
face runout at any point being the difference between these readings.
b. Install the outer races of the eccentric bearings (13) and the outer race retainer ring (3) in
the three eccentric straps. Outer race retainer ring must be positioned so that oil scoop is at
the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to the following torque:
safety wire heads.
F-500 60 90 N·m (44 66 ft·lbs)

F-800 60 90 N·m (44 66 ft·lbs)
F-1000 60 90 N·m (44 66 ft·lbs)
NOTE: The inner and outer races of the eccentric bearings are matched and must not be
intermixed.
c. Install the outer race of the crosshead bearings (19) in the three eccentric straps .It is
preferred that the outer race assembly be “pressed” into position of frozen in “dry ice” or a
deep freeze until it can be inserted into the bore. Under emergency circumstances, the outer
race assembly can be installed by using a large torch and heating the eye of the eccentric
strap . DO NOT EXCEED 149 (300 F) (Use Tempil-Stik) and DO NOT USE WATER to
cool the strap.
NOTE: The inner and outer races of the crosshead bearings are matched and should not be
intermixed.
d. Install the inner race of the crosshead bearing on the crosshead pin and mark according to
their respective eccentric strap positions. Remove all nicks and burrs before shrinking race
into place. Refer to bearing fit Position H Chart II.
e. Install inner race of the center eccentric bearing on the shaft. slide center strap into position
and install inner race clamp (5). Tighten socket head screws (8A) in clamp to the following
torque.
F-500 24 36 N·m (18 26 ft·lbs)

F-800 60 90 N·m (44 66 ft·lbs)
F-1000 60 90 N·m (44 66 ft·lbs)
f. Install snap ring (7) in the groove on RH eccentric and shrink inner race of eccentric
bearing on shaft. After sliding the RH eccentric strap into position, install inner bearing
retainer (14).
Tighten inner race retainer bolts (8) to the following torque

F-500 60 90 N·m (44 66 ft·lbs)
F-800 60 90 N·m (44 66 ft·lbs)
F-1000 60 90 N·m (44 66 ft·lbs)
g. Install the LH eccentric bearing (other than for snap ring) and eccentric strap under the
same procedure outlined in step (f) above.
h. Place main bearings (9) in the main bearing carries (10 RH and 11 LH) and install outer
race retainer (12) and retainer bolts (15). Tighten bolts to the following torque:
F-500 24 36 N·m (18 26 ft·lbs)

F-800 60 90 N·m (44 66 ft·lbs)
F-1000 60 90 N·m (44 66 ft·lbs)
NOTE: Even though the main bearing carriers (10 RH 11 LH )have different configurations on
the OD, they are interchangeable and will fit into the pump frame on either side. The purpose
of the shoulders on the OD of one of the carriers is to locate and retain the crankshaft in its
respective position in the frame.
i. After installing the two main bearing spacers (16), shrink main bearings (9) on each end of the
shaft. Install inner race retainers (17) and retainer bolts (18) . Tighten retainer bolts to the
following torque:
F-500 24 36 N·m (18 26 ft·lbs)
F-800 60 90 N·m (44 66 ft·lbs)
F-1000 60 90 N·m (44 66 ft·lbs)
4.5 Installing Crankshaft Assembly In Frame
In order to obtain a more precise fit between the main bearing housing and the frame bore on
BS F-Series pumps, the installation procedures outlined below are to be followed (Refer to Fig.
16)
Fig. 16
4.5.1 Place piece of wood between eye of eccentric strap and crosshead guide (as shown in Fig.
17 17A) to protect guide from scoring or gouging as the straps are sliding into position.
4.5.2 Rotate the main bearing carrier so that the two flat spots (180 apart) are parallel with
the main bearing bolt holes, and slowly lower the crankshaft into position.(The flat spot
provides clearance for the main bearing bolts.)
4.5.3 After placing crankshaft in the frame, and before installing the main bearing caps, check
the rollers in the main bearings to assure that each row of rollers in each bearing is equally
loaded. Equal loading is obtained by positioning the floating bearing carrier so that the
same number of inner and outer rollers supporting the weight of the crankshaft in each
bearing are tight. Because of tolerances , etc., the total number of tight rollers could very
slightly between individual bearings.
4.5.4 Install and shim main bearing caps to obtain 0.10mm(0.004”) clamp or preload on the main
bearing carrier is obtained by placing the correct amount of shims under the main bearing cap.
The required amount of shims is determined as follows: Fig .16
a. Install 0.50mm(0.02’’) shims under both ends of the main bearing cap.
b. Place a piece of lead wire (approximately 0.8mm diameter) or Plastigage between OD of

bearing carrier and ID of bearing cap ,as near center of bearing cap as can be determined, and
tighten main bearing cap bolts to torque values shown in Chart III.
c. Remove main bearing cap and determine clearance between bore of cap and OD of bearing
carrier by either mikeing thickness of lead of measuring compressed dimension of plastigage.
d. Using this dimension , calculate the required thickness of shims as follows:
Subtract thickness of compressed lead or Plastigage from the original 0.50mm shim
thickness. Then subtract. 0.1mm for preload. The result is the correct shim thickness
required.
Example:
0.50mm Original shims 0.002”
Less 0.13mm Lead Thickness Less 0.005”
0.37mm 0.015”
Less 0.10mm Clamp Fit Less 0.004”
0.27mm Correct Shim Thickness 0.011”
NOTE: Machining tolerances make it necessary to determine individual shim requirements
for each (right hand and left hand) main bearing cap.
e. Install main bearing caps with the correct amount of shims as determined above , and
tighten main bearing bolts to torque values shown in chart III.
f. Again check inner and outer row of rollers on each bearing as previously outlined to assure
equal loading is still present on each bearing.
CHART III
Torque Thread Wrench Size

N.m ft. Size mm in
lbs
F-500 4065 3000 1 3/4”-8UN 55
F-800 8620 6360 2 1/4”-8UN 76.2 3”
F-1000 11920 8800 2 1/2”-8UN 82.5 3 1/4”
4.6 Installation Of Crosshead Quides For F-800/1000
When installing crosshead guides observe the following procedures and precautions:
4.6.1 Thoroughly clean all dirt or contamination and remove all burrs or rough edges from both
sides of the guides and the frame bore where the guides fit.
4.6.2 If old guides are to be reused, inspect the wearing surfaces for wear and scoring streaks.
NOTE: For F-800, F-1000, upper and lower crosshead guides are NOT interchangeable. In these
pumps, the guide are machined so that the lower guide places the crosshead on frame
centerline, and upper guides are machined to afford proper crosshead to guide clearance.
4.6.3 Install upper and lower guides, Torque guide screws to 200 270N·m (150 200ft·lbs)
4.6.4 Check between frame and guides at points A, Fig. 18, with 0.05mm (0.002 ) feeler gauge to
make sure gauge to make sure guides fit into bore.
4.7 Installing Crosshead Guide For F-500
When crosshead guides become worn or damaged, they should be replaced, observing the
following precautions. (Note: The crankshaft must be pulled to allow clearance for removal
and installation of the guides.)
Fig.16B
4.7.1 Remove worn or damaged guides.

4.7.2 Thoroughly clean the frame bore and the mating surfaces of the frame wall and crosshead
guide (Position A)These surfaces MUST BE ABSOLUTELY FREE OF DIRT OR
FOREIGN MATERIAL in order for crosshead guide to give proper alignment between the
power end fluid end parts.
4.7.3 Slide 0-ring seal (1) over end of crosshead guide. Coat with light oil or anti-seize compound,
and position guide into frame bore. Use caution to prevent damage to the O-ring seal. The
crosshead guide is symmetrical and can be rotated top to bottom. The fit between OD of
crosshead guide and frame bore (Position B) is shown below:
L 0.102 mm – L 0.203mm ( L 0.004 - L 0.008 )
4.7.4 Install crosshead guide retainer bolts (2) and tighten crosshead guide into place. Tighten bolts
to the torque shown below:
675-1012N·m(500 750 ft·lbs)
For more uniform make –up, tighten bolts in a cross-cross procedure.
4.7.5 Check mating surfaces (position A) for metal-to-metal make-up by Attempting to insert a
0.025mm-0.050mm feeler gauge between the two parts.
4.7.6 Install the two oil lines (3 and 4).
NOTE: The crosshead guides are symmetrical and can be rotated from top to bottom. In
emergencies where bottom surface of guide becomes damaged and time does not permit a new
part to be obtained, the damaged guide can be rotated 180° to allow the crosshead to run on a
new surface. It will be necessary to pull crankshaft for clearance to rotate the guide. The
damaged can then be replaced at a more convenient time.
4.8 Installation Of Crossheads
The crossheads in the pumps can be installed through the front (fluid end ) or back end of the
crosshead guide .
Reference Fig.18.18A. When installing crossheads, observe the following precautions:
Fig.17 Fig.17A
4.8.1 Thorughly clean all dirt or contamination and remove all burrs or rough edges from OD of
the crosshead, crosshead pin bores, and inner bore of crosshead guide. Dry crosshead pin
bore so taper bore connection will make metal to metal See Note.
4.8.2 Position “eye” of eccentric at the opening in the side of the crosshead guide. Block
eccentric strap so that crosshead will clear the “eye” as it is sliding into position to where the
crosshead pin holes are in alignment. Refer. Fig 17.17A
4.8.3 Install the left hand crosshead first, Rotate eccentric assembly to move “eye” into center
crosshead and right hand eccentric strap “eye” back, affording clearance to install
center pin through right hand crosshead inspection door. Remove diaphragm stuffing box
plate (1,Fig.18) and install right hand crosshead through this bore. Slide into place and
install crosshead pin.
4.8.4 Install crosshead pin retainer (2) and retainer bolts (3) and rotate pin until the four crosshead
retainer to crosshead bolt holes (4) are in alignment. Install the crosshead retainer to
crosshead bolts and make up hand tight. Ref. Fig 18.18A
Fig.18 Fig.18A
Referring back to fig. 11.11A crosshead pin (4) can be installed without regard to oil holes (5).
Two holes are provided so the pin can be rotated 180 in relation to pin to retainer plate
screws (3).
Seat crosshead pin in tapered bore by bumping large end with a light blow. Tighten retainer
bolts (3 and 4,Fig.18) to the following torque and safety wire:
F-500 120 135 N·m (90 100ft·1bs)
F-800 190 205 N·m (140 150 ft·1bs)
F-1000 225 240 N·m (165 175 ft·1bs)
DO NOT EXCEED THESE VALUES. USE TORQUE WRENCH.
NOTE: To pull the crosshead pin, remove the four crosshead retainer. to crosshead bolts (4)
and screw two of the bolts into the “jack screw” holes (5). Tighten the two jack screw
bolts until the pin breaks loose. Complete removal of crosshead pin retainer plate (2) and
slide pin out of bore.
4.8.5 Check running clearance of crosshead by sliding long “feeler” gauges between top of
crosshead guide bore. The clearance should not be less than 0.508mm (0.020 ). Check with
long feeler gauge over entire surface of crosshead.
NOTE: Less running clearance at center of crosshead can be caused by “swelling” from
overtightening the crosshead pin retainer bolts (4). If present, loosen pin and retighten
into place by using the make-up torques shown in paragraph 4.
4.8.6 For F-500
Install the center crosshead first. Crosshead pin is installed through the top of the pump by
removing the inspection cover. Slide crosshead pin into bore but do not seat taper until the
crosshead pin retainer (2) Fig.18A has been installed.
NOTE: If old crossheads are to be reused, inspect the sliding surfaces for wear or scoring. If
necessary, the crosshead may be switched to opposite sides of the pump and rotated
180 to provide a smooth surface for the bottom of the crosshead.
The center crosshead can be rotated 180 and the crosshead pin installed from the
opposite side of pump.
4.9 Checking Crosshead Alignment
In order for the pistons to run true in the liners, the crosshead must travel in a straight line
along the horizontal centerline of the frame bore. to check and adjust crosshead alignment,
proceed as follows:
4.9.1 Remove diaphragm stuffing box from the diaphragm plate, (Fig,18).Do not remove the plate,
4.9.2 Position crosshead at the extreme front of its stroke. With inside calipers or telescoping
gauges, accurately measure the distance from the diaphragm plate bore to the crosshead
extension rod at the top and bottom. Compare the two measurements to determine the
position of the rod relative to the centerline of the bore.
4.9.3 Rotate pump to extreme rear of stroke and take measurement again at the same place.
Compare these measurements to the ones taken at the front of the stroke to determine if
crosshead is running horizontal.
4.9.4 If the centerline of the extension rod is more than 0.381mm ( 0.015 ) low in the diaphragm
plate bore, shims should be inserted under the lower guide to bring the extension rod back
to center, provided there is ample clearance between the top of crosshead and upper
crosshead guide. It is normal for the lower guide to wear more at the rear due to heavier
loading at this point because of the angle of the eccentric strap. It is permissible to shim the
guides on a taper if is done accurately to provide firm support for the guide. Do not shim
guides to less than 0.50mm (0.020 ) clearance. Large crosshead clearances are acceptable
due to characteristics of triplex pump operation,the crosshead pressure is always on the
lower guide.
4.9.5 Cut shims from steel shim stock long enough to reach completely across the guides. Cut
tabs on the side to bend down over frame supports to hold them in place. Refer to items 3
and 4 under Installation of Crosshead Guides.
4.10 Fluid End Maintenance
For many years, the fluid end of a pump was considered a non-wearing part which did not
cause any concern other than possible infrequent repairs or replacements resulting from fluid
cuts or washouts. However, the higher pressures of the present-day drilling requirements
have resulted in higher stresses being imposed on the fluid end which, when combined with
the corrosive characteristics of the drilling fluid, have resulted in the demand that more and
better maintenance be given to the fluid end parts and pieces if a reasonable operating life is
to be obtained. A few of the obvious points are as follows:
2. a .Make sure all valves on the discharge side of pump are opened before pump is put into
operation. Kicking pump in against a closed valve can often be the start of a fatigue crack.
An open crack may not necessarily occur at the precise moment, however a small crack could
occur and start the process of “corrosion fatigue failure”
b. Do not engage pump clutch when prime mover is running at a high rate of speed. To do can
cause undesirable shock loads against both power end and fluid end.
c. Properly maintain pressure relief valve to assure it is set for the pressure rating on the liner size
being used.
d. Do not operate the pump for an extended period of time if a severe fluid knock is present.
e. Properly prepare fluid end for storage. When pump is to be shut down or not operated for a
period of ten days or more, it is recommended that the fluid end parts such as liners, pistons,
rods, etc, be removed from the pump and the fluid end flushed out completely with fresh water,
After a thorough flushing, apply grease or a rust preventative to all of the machined surfaces
such as valve pot cover threads, valve pot cover gasket surfaces, valve seats, liner bores, etc. the
parts removed from the pump including liner, piston rods, etc., should of course be protected
from the elements. This will not only extend the life of the fluid end through resistance to
corrosion, but will also protect the usable life still left in the expendable parts and maintain them
in good condition for installation in the pump at the next start-up period.
Maintenance and repairs should be made on the fluid end assembly by observing the following
precautions. Refer to figure 19.19A 19B.
The fluid end assembly for these triplex pumps consists of three forged cylinder blocks,
complete with valve pot covers and cylinder heads, a suction manifold, and a discharge
manifold.
4.10.1 Fluid Cylinder blocks
The three separate fluid cylinder blocks (1) blot metal –to-metal to the power end frame
through retainer studs (2) , Alignment with the power end frame bores is obtained through the
“pilot” boss on fluid end .
However , to obtain accurate alignment ,all nicks or burrs must be removed from “pilot” boss
and frame bore and all dirt and foreign matter cleaned from the mating surfaces; otherwise
cylinder blocks could make up in a “cocked” or misaligned position.
The fit between “pilot” boss and frame bore (Position A) is as follows:
Install the three cylinder block nuts to the torque values shown in Chart V.
4.10.2 Suction Manifold
The suction manifold (3) bolts to each cylinder block and is sealed through the 0-ring in the
connection flange. Thoroughly clean o-ring groove, the 0-ring sealing surface on bottom of
the cylinder block, and replace o-ring seal before bolting manifold into position. The flange
connection MUST make up metal-to-metal to retain the o-ring seal, therefore any nicks,
grooves or washouts on the sealing surface must be repaired before installation. Ref. Welding
and Repair Section in this manual for repair procedures.
Start all suction manifold bolts (5) in the three cylinder blocks before tightening. Tighten to
torque values shown in Chart V.
4.10.3 Discharge Manifold
The discharge manifold bolts to each cylinder block and is sealed through the 0-ring in the
connection flange.
Thoroughly clean the 0-ring groove, the 0-ring sealing surface on face of the cylinder block
before bolting the manifold back into position. The flange connection MUST make up
metal-to-metal to retain the 0-ring seal, therefore any nicks, grooves, or washouts on this
sealing surface must be repaired before installation. Ref. Welding and Repair Section in this
manual for repair procedures.
Start all discharge manifold bolts (8) in the three cylinder blocks before tightening . Tighten
to torque values shown in Chart V. Tight cylinder block to power frame stud nuts to torque
values shown in Chart V.
4.10.4 Cylinder Head Thread Ring
A replaceable cylinder head thread ring (9) is bolted on to the face of the cylinder blocks. The
thread ring must make up metal-to-metal with face of cylinder blocks in order for the axis of the
threads to be perfectly square with the cylinder. Block bore . Therefore, make sure all burrs,
extrusions, or foreign matter is removed from the mating faces before making installation.
NOTE: Install thread ring so that the “bleed hole” is in the down position. Tighten the cylinder
head thread ring stud nuts (10) to the torque values shown in Chart V.
Chart V
TORQUE TORQUE
Position ITEM
N.m ft. lbs
CYL BLOCK TO POWER F-500/800/1000
2 2170 1600
END
F-500 5 200 150
SUCTION MANIFOLD
F-800 F-1000 5 325 240
F-500 8 960 710
DISCHARGE MANIFOLD
F-800 F-1000 8 1355 1000
F-500 10 960 710
THREAD RING
F-800 F-1000 10 1840 1360
Fig .19
CHART VI
F-500
POSITION
mm in
A 216.03-216.15 8.505-8.510
B 190.63-190.70 7.505-7.508
C 317.5 12-1/2
D 155.58-155.70 6.125-6.130
E 136.53-136.65 5.375-5.380
F 126.87-127.00 4.995-5.000
G 135 5-5/16
H 231.8 9-1/8
J 203.2 8
K 63.5 2-1/2
L 76.2 3
Fig .19A
CHART VII
F-800 & F-1000

POSITION
mm in
A 222.38-222.50 8.755-8.760
B 197.05-197.25 7.758-7.766
C 339.7 13-3/8”
D 172.08-172.21 6.775-6.780
E 152.65-152.78 6.010-6.015
F 142.80-142.93 5.622-5.627
G 101.6 4”
H 114.3 4-1/2”
4.11 Welding And Repairs
On occasion where washouts or normal wear cause repairs to be made to the fluid end bores,
the following welding procedures and precautions should be closely followed. Machine bore all
dimensions to those shown in applicable chart VI, VII, VIII, and in all cases maintain the
shoulders (where liners, covers, etc., seat) 90 to the axis of the bore.
Welding Procedures:
Weld repairs can usually be separated into two categories:
(1) Washes, and (2) Cracks. Listed below is the basis information for the repairs:
Washouts: -Weld as’ 30 carbon Steel

-Clean area by grinding or Arc-air
-Before starting any welding procedure, make sure the electrodes are dry of moisture,
and if necessary, put in oven and bring up to temperature required to drive out
moisture.
-Spot heat area to 250 -350 F(120 -180 C) out in all directions for a
minimum of 75mm(3”)
-Use AWS-ASTM E-60-7018 low hydrogen rods.
Example-Adam-Arc 7018.
-Temperatures should be brought back to 250 -350 F(120 -180 C) after each
pass and maintained throughout the welding. After welding is completed and area
cleaned, heat to 250 -350 F(120 -180 C) and allow to cool .
Cracks:- Grind out all of crack .Any attempt to burn out a crack will only result in the crack
progressing faster than the material can be burned.
- Follow the same welding procedure as above.
Preheating:
- The purpose of preheating is to expand the area being repaired so that as the cooling
process takes place, the welded area and the preheated area will cool more
uniformly .Preheating also prevents hard spots from forming between the base
metal and the welding by eliminating a thermal shock as the weld is being applied.
This hard spot will ,of course, be a good place for fatigue cracks to occur.
4.12 Repairs to Valve Pot Cover Bore
When making repairs to washouts in the valve pot cover bore, it is extremely important that the
surface where the valve cover seats is either “machined” or “ground” perfectly flat and 90 to
the axis of the threads. As shown in Fig. 20, the valve pot cover gasket (1) seats into the
counterbore at top of valve cover deck, and as the cover makes up metal to the valve deck, the
gasket is confined within its counterbore Obviously ,any high spots on the valve cover deck
from weld repairs. or any low spot from over-grinding of the repairs can result in a gap between
top of the valve cover deck and bottom of the valve cover, through which the valve cover gasket
can be extruded under pressure.
The high or low spot can also cause valve covers to make up in a “cocked” position and result
in severe thread damage (cracks) due to the axis of the two mating threads being out of square.
Fig .20
4.13 Operating Maintenance
Proper maintenance of the pump in time is the necessary measure to assure the pump working
and prolong the service life. For using any pump, maintenance should be paid more attention to.
4.13.1 Daily Maintenance

1) After stopping the pump, check the oil level of power end, at least once a day. If chain drive is
used, the oil level of chain box should be checked.
2) Check the working situation of liner and piston, it’s normal that a little mud is taken out with
piston. If there is leakage, the piston should be changed. Checkthe abrasion of liner inner bore,
if the abrasion is severe, the liner should be changed in time.
3) Check the liner compartments of the frame. The mud and contamination should be cleaned.
4) Check the water tank of spray pump. The water or oil should be supplied if there is not
enough. The polluted water should be changed and the water tank should be cleaned.
5) Check if the pressure of discharge pulsation dampener meets the requirements.
6) Check the reliability of relief valves, if necessary, they should be changed.
7) Check the lubricating oil pump for the variation of pressure gauge, if the pressure is very low
(lower than 0.035Mpa) or no pressure, check if the suction and discharging filter screen are
plugged.
8) Loose the coupling of piston rod every day, check if the pyramidal face of coupling and the
junction face of piston rod and extension rod are clean, rotate the piston rod a quarter round
and tighten. The purpose of doing that is to make the wearing face evenly and prolong the
service life of liner and piston.
9) Before tightening the valve cover, the lubricating grease should be coated on the threads and
be checked once four hours for loosing.
10) Check the alarm bore of valve covert seal and liner seal (including the seal between the
wearing plate and cylinder), if the mud discharges, the relative seal ring should be changed.
4.13.2 Weekly Maintenance
1) Disassemble the valve cover and clean them every week, meanwhile coat the molybdenum
disulfide complex calcium base grease. Check the inner sleeve of valve guide, if there is sharp
abrasion ( that means the clearance between the valve guide pole and guide exceeded 3mm),
it should be changed to avoid the guide failing to guide the valve motion in the right way and
accelerating the abrasion of valve.
2) Check the valve and valve seat, change the worn or pierced valve body, valve rubber and
valve seat (when changing the valve seat, the valve body should be changed at the same time).
Check the spring and change the broken or inelastic spring.
3) Check the locknuts of piston. The corrosive or damaged locknuts should be changed. (The
seal rings in the locknuts will fail after the locknuts are tightened three times.)
4) Drain water one time from the plug of drain flange until oil comes out.
5) Check and clean the filter screen in the lubricating oil line.
4.13.3 Monthly Maintenance
1) Check all the stud bolts and nuts of fluid end. For example: nuts among cylinders, nuts
connecting the cylinder to frame, the bolts and nuts on the suction and discharge manifold. If
they are loose, they should be tightened to the specified torque value.
2) Check the seal rings in the packing box of extension rod. The worn one should be changed.
Usually, change it at least once every three months. Attention should be taken to the oil seal
position when changing (the lip should be inward).
3) Remove and clean the filter installed in the discharge manifold.
Change the dirty oil in the oil pool of power end and the oil groove of crosshead every six
months. Clean these oil grooves at the same time.
4.13.4 Yearly Maintenance

1) Check if the crosshead guide is loose, if the crosshead running clearance conforms to
requirements. The clearance can be adjusted by adding shim under the guide or rotating
the crosshead 180 .
2) Check the whole pump completely every two years or three years, check if the main bearing,
connecting rod bearing, crosshead bearing, input shaft bearing are worn or outworn. They
should be changed if they can’t be used any more.
3) Check the wear of gears, if they are worn sharply, the drive shaft and the driven shaft should
be turnaround installed to use the face that isn’t worn.
For the convenience of maintenance, checkpoints are listed in chartVII and Fig.24.
4.13.5 Cares should be taken for the following in maintenance
1). Before tightening the coupling connecting the extension rod and piston rod, the 25 taper face
should be cleaned.
2) When changing the liner, the liner seal ring should be changed as well.
3) After stopping the pump in winter, the mud in the valve compartment and liner should be
discharged and cleaned completely.
4) Cover each inspection hole to avoid the sand dropping into the lubricating oil.
5) The discharge pulsation dampener is only allowed to charge inert gas (such as nitrogen) or air.
No inflammable and explosive gases are allowed such as oxygen, hydrogen etc.
Chart VII Maintenance List
Interval No. Maintenance

Daily 1 Check the oil level after stopping the pump, if it is too low, it should be
added to required level.
Check if the readings of pressure gauge of lubricating oil pump are
Daily 2
normal. When the pressure is too low, the cause should be found at once.
Daily 3 Check if the dampener works normally
Daily 4 Fill the cooling lubricant up to the spray pump water tank when it’s not
enough. Change it when it deteriorates.
Daily 5 Check the liner compartments. Clean it when necessary.
Daily 6 Check if the plunger liner seal leaks, change it when necessary.
Daily 7 Check the piston and liner for leakage, change them when necessary.
Loose the coupling of piston rod one time daily, rotate the piston rod a
Daily 8
quarter turn and then tighten the coupling back again.
Check if the valve bonnets are loose every four hours. Coat lubricant on
Daily 9
the thread when tightening.
Daily 10 Check if the safety valves are reliable.
11 Check if the pre-charging pressure of discharge pulsation dampener is
Daily
normal when stopping the pump.
12 Observe the alarm bore, if the mud is discharged, the related seal ring
Daily
should be changed.
13 Disassemble the valve cover and clean it, coat it with molybdenum
Weekly
disulfide complex calcium base grease.
Weekly 14 Check the inner sleeve of valve guide, if it’s worn, it should be changed.
15 Check the suction and discharge valve body, valve seat and valve rubber,
Weekly
change the damaged one.
16 Check if the locknuts of piston are corrosive or damaged. Change if they
Weekly
are damaged (normally, change after using three times).
Weekly 17 Check the filter screen of lubricating system. Clean it if it is plugged.
18 Loosen the plug of drain flange, discharge the dirt and water in the oil
Weekly
pool.
19 Check the bolts of fluid end, the loose or damaged bolts should be
Monthly
tightened or changed.
20 Check the seal ring in the packing box, the worn one should be changed at
Monthly
least once every three months
Monthly 21 Check the filter in the discharge pipe. Clean it if it is plugged.
22 Change the dirty oil in the oil pool of power end and crosshead oil groove
Monthly
and clean them every six monthes.
23 Check the wear of crosshead, if necessary, use the crosshead after rotating
Yearly
180 .
24 Check if the guide is loose, check if the crosshead clearance conforms to
Yearly
requirements, otherwise, they should be adjusted.
25 Check the wear of tooth face of the pinion and the gear, if necessary, use
Yearly
them reverse face.
26 Check if the pinion shaft and crankshaft are all right. Measures should be
Yearly
taken abnormal phenomena.
Yearly 27 Check the bearing of power end. The damaged one should be changed.
28 Check the seal of rear cover and crank shaft end cover, if the seal is not
Yearly
good, it should be changed.
4.14 Troubleshooting
During the running of the pump, if there are troubles, the reason should be checked and the
trouble should be solved, otherwise, they will affect the normal working of the pump.
4.14.1 Trouble of fluid end
Trouble Cause Troubleshooting

1.The charging piping is not 1.Tighte the flange bolts of
1.The ressure readings
sealed off and the air gets charging piping or change
become low and the
into the pump. the gasket.
discharge reduces or no
2.The suction filter screen is 2. Stop the pump and clean
mud discharged.
plugged. the suction filter screen.
1.Change the damaged piston
2. Uneven discharge. The
1. A piston of a valve is worn and check the valve to find
pressure gauge
out or damaged. if it’s damaged or plugged.
fluctuates. The charging
2. There is air in the pump 2. Check if the charging
piping has abnormal
cylinder. piping and valve cap are
noise.
sealed off.
3.There is severe slap in 1.The piston nuts are loose. 1.Tighten the piston nuts.
the liner. 2.The liner cover is loose. 2.Tighten the liner cover.
3.The suction is not good 3.Check the reason of
caused water dash. improper suction.
4.The mud leakage from
1.The valve cap is not
the alarm bore of valve 1.Tighten the valve cap.
tightened.
cap, cylinder and liner 2.Change the seal ring.
2.The seal ring is damaged.
seal.
1.The charging connector is
5. The discharge pulsation plugged. 1.Clean the connector.
dampener can’t be 2.The bladder of the pulsation 2.Change the bladder.
charged or it leaks after dampener is broken. 3.Repair or change the needle
charging. 3.The needle valve is not valve.
sealed.
6.The diesel is The discharge filter drum is Remove the filter screen and
overloaded. plugged. clean it.
4.14.2 Trouble of power end
Trouble Cause Troubleshooting

1. Overheat of bearing 1.The oil pipe or oil port is 1. Clean the oil pipe or oil port.
plugged. 2. Change oil.
2.The lubricating oil is too 3. Repair or change bearing.
dirty or deteriorated. 4. Add proper amount of oil.
3.The rolling bearing is worn
or damaged.
4.The lubricating oil is too
much or too little.
2. There is slap on the power 1. The crosshead guide is 1. Adjust the clearance or
end. worn out sharply. change the worn guide.
2. The bearing is worn out. 2. Change the bearing.
3. The guide is loose. 3. Tighten the bolts of guide.
4. There is water hammer on 4.Improve the suction
the fluid end. performance.
NOTE:Besides the above estimated trouble,if other adnormal phenomena are found,
The reasons should be gound according to the trouble spot.after troubleshooting,the pump can
run norm
Fig.21
5.APPROXIMATE WEIGHTS OF PUMP ASSEMBLIES
BS F-500 BS F-800 BS F-1000

lbs kg lbs kg lbs kg
Pinion Shaft 1,062 482 1,630 740 1,709 775
Crankshaft Assy 4,526 2,055 7,458 3,383 10,479 4,744
Crosshead 115 52 258 117 363 165
Crosshead Pin & Retainer 31 14 123 56 177 80
Gear Case Cover 302 137 262 119 340 154
Suction Manifold 337 153 429 195 704 319
Discharge Manifold 663 301 696 316 717 325
One-third Fluid and
1,068 485 1,140 517 1,140 517
Section-Studded
6 . Storage
1) When the pumps are not used for a long time, they should be stored.
2) Before storing, clean it carefully, empty each part of fluid end and clean it with water.
3) Discharge the engine oil in the bottom of gear box of power end completely and
remove the deposits.
4) Coat viscous lubricants on the finished surface of all bearings, crossheads, gears, piston
rods, extension rods etc.
5) Coat grease on the machined surface of each parts of fluid end.
6) Cover the suction inlet and discharging outlet with blind flange.
7) The nose end cover, rear cover and the inspection hole cover of crosshead should be
covered.
7 Explains for order

7.1 Provided range of mud pump
-Completely MUD PUMP basic parts; spray pump; pulsation dampener; safety value;
tools; spare parts for one time change of rubber seals.
-Not including sprocket and big skid.
-If not be special required by users, spray pump is droved by belt and lubrication pump
is inner droved style by big gear.
-Normally, 170liners and pistons are assemblied in the pump when it is transported to
users.
7.2 F-series mud pumps divided into two basic styles, one is metric screws pump, the
other is American style screws pump. Users choose it due to their own demands and
declare when ordering.
SECTION 2
BS F-500/800/1000 TRIPLEX PUMP PARTS BOOK

PARTS BOOK DRAWING LIST
DRAWING DESCRIPTION DRAWING NO. OR PART NO PAGE
F- 500/800/1000 GENERAL ASSEMBLY AH05010200/ AH08010200/ AH10010200 67
F-500/800/1000 FLUID END ASSEMBLY AH0501020500/ AH0801020500/ AH1001020500 70
F-500/800/1000 DISCHARGE STRAINER & ACC Y MANIFOLD 73
AH0501011400/ AH1001021100/ AH1001021100
F-500 CROSSHEAD ASSEMBLY AH0501020400 74
F-800/1000 CROSSHEAD ASSEMBLY AH0801020400/AH1001020400 76
F-500/800/1000 PINION SHAFT ASSEMBLY AH0501020300/AH0801020300/AH1001020300 78
F-500 800/1000 CRANKSHAFT ASSEMBLY AH0501020200/AH0801020200/AH1001020200 79
F-500 LUBRICATION ASSEMBLY AH0501020600 81
F-800/1000 LUBRICATION ASSEMBLY AH0801020500 /AH1001020600 84
F-500/800/1000 PISTON & LINER WASH AH0501020800/AH0801020800/AH1001020800 87
F-500/800/1000 TOOL LIST AH0801021000/ AH1001021300 90
F-500/800/1000SPARE PARTS LIST AH0501021400/AH0801011100/AH1001021000 91

F-500/800/1000 GENERAL ASSEMBLY
ITEM PART No
QTY DESCRIPTION
N0 F-500 F-800 F-1000
1 1 Frame Assembly AH0501020100 AH0801020100 AH1001020100
Crank Shaft
2 1 AH0501020200 AH0801020200 AH1001020200
Assembly
Pinion Shaft
3 1 AH0501020300 AH0801020300 AH1001020300
Assembly
Crosshead
4 3 AH0501020400 AH0801020400 AH1001020400
Assembly
Fluid End
5 1 AH0501020500 AH0801020500 AH1001020500
Assembly
Lubrication
6 1 AH0501020600 AH0801020600 AH1001020600
Assembly
7 1 Skid AH0501020700 AH0801020700 AH1001020700
Piston & Liner

8 1 AH0501020800 AH0801020800 AH1001020800
Assembly
Gasket ,Inspect
9 AH10010109 (1) AH10010109 (2) AH10010109 (2)
Door
10 1 Breather Cap T515-101.00 T515-101.00 T515-101.00
11 Loctite 277 170506010100243000 170506010100243000 170506010100243000
12 1 Cover Assembly AH0501012200 AH0801011600 AH1001012300
13 2 BS Name Plate AH05010209 AH08010209 AH10010209
14 1 Cover Plate AH0501011000 AH0801011000 AH1001011100
15 1 Gasket AH05010111 AH08010111 AH10010112
Cap Screw
16 14 T500-1001 T500-1001 T500-1001
1
/2-13UNCX1
Oil Level Name

17 AH10011013 AH10010113 AH10010113
Plate
Oil Level Indicator

18 2 AH1001011400 AH1001011400 AH1001011400
Assy
19 Gap Screw T500-1009 (8) T500-1009 (8) T500-1023 (10)

ITEM PART No
QTY DESCRIPTION
N0 F-500 F-800 F-1000
1-8UNC×3 1-8UNC×3 1-8UNC×31/2
Clean Out
20 1
Cover<I>
Clean Out
21 AH1001011500 2 AH1001011500 2
Cover<II>
22 Gasket AH10010116 (2) AH10010116 (2)
Cap Screw
23 T500-1019 36 T500-1019 16
1
/2-13UNCX11/2
24 2 Crosshead Door AH05010112 AH08010112 AH10010117
25 2 Gasket AH05010113 AH08010113 AH10010118
Washer14 420501036120200000 420501036120200000 420501036120200000

26
GB848-85 38 50 22
Rivet 3X10
27 6 420999050603001000 420999050603001000 420999050603001000
GB827-76
T500-1009 (12) T500-1009 (8)

28 Bolt
1-8UNC×3 1-8UNC×3
29 Nut 1-8UNC T501-1003 (12) T501-1003 (8) T501-1003 (10)
Lock Washer 27 420503011271600000

30 420503011271600000(12) 420503011271600000 (8)
GB93-76 (10)
T500-1002 (26) T500-1010 (24)

31 Cap Screw
1
/2-13UNCX11/4 5
/8-11UNC×15/8
Washer16 420501036160200000
32
(GB848-76) (24)
Gasket, Gear 530302022500001000 530302022500001000 530302022500001000

33 1
Case Cover 25×10×4000 25×10×4000 25×10×4880
34 2 Thread Plug T506-1006 ---------- ----------
T500-1008
35 4 Cap Screw
5
/8-11UNC×13/4
Nut 5/8-11UNC T501-1002

36 4
5
/8-11UNC
37 4 Lock Washer 16 420503011161600000

ITEM PART No
QTY DESCRIPTION
N0 F-500 F-800 F-1000
(GB93-87)
38 Washer 14
Discharge Oil
39 1 AH0501021300 ---------- ----------
Pipe
40 1 Inspect Door AH0501021200 ---------- ----------
Gasket, Inspect
41 1 AH05010117 ---------- ----------
Door
Stud
42 1 ---------- ----------
1
/2-13UNCX 13/4
43 Copper Net ---------- ----------
Cap Screw M4X16

44 8 420101050604001600 420101050604001600 420101050604001600
GB818-85
F-500/800/1000 FLUID END ASSEMBLY
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
Fluid End Studded AH050102050100 AH080102050100 AH080102050100
1 3
Assy
2 3 Thread Ring AH0501010502 AH1001010502 AH1001010502
3 3 Cylinder Head AH0501010503 AH1001010503 AH1001010503
4 6 Liner Seal AH0501010504 AH1001010504 AH1001010504
5 3 Cylinder Head Plug AH0501010505 AH100101050500 AH100101050500
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
6 3 Liner Cage AH0501010506 AH1001010506 AH1001010506
O-ring 530301010750053007 530301010975035507 530301010975035507
7 3
GB3452.1-82 75×5.3 97.5×3.55 97.5×3.55
8 1 Discharge Manifold AH0501010507 AH0801010501 AH1001010507
9 3 Valve Cover Seal AH0501010508 AH1001010508 AH1001010508
T500-7001 T500-7002 T500-7002
10 16 Stud
11/4-8×3/8 11/2-8×101/2 11/2-8×101/2
T501-2002 T501-2001 T501-2001
11 32 Nut 1 1
1 /4-8N-2B 1 /2-8N-2B 11/2-8UN
12 3 Valve Pot Cover AH0501020502 AH0801020502 AH0801020502
13 3 Valve Guide AH0501010510 AH1001010510 AH1001010510
14 3 Spring Guide AH100101051100 AH100101051100 AH100101051100
15 3 Valve Guide Retainer AH0501010511 AH1001010512 AH1001010512
3 3
16 12 Bolt /8-16UNCX /4 AH0501020509 AH0501020509 AH0501020509
Wire 1.6×1830 040104030160001900 040104030160001900 040104030160001900
17 1
GB4240-84
18 6 Valve Spring AH00000101 AH00000101 AH00000101
19 6 Valve Assy AH0000020500 AH0000020100 AH0000020100
20 3 Nut 11/2-8UN,Piston T501-303.00 T501-303.00 T501-303.00
21 3 Piston AH100102050100 AH100102050100 AH100102050100
O-ring 41.2×3.55 530301010412035507 530301010412035507 530301010412035507
22 3
GB3452.1-82
Pipe Connector AH080102050400 AH100102050400
----------
23 3 1/8 1/4
Copper Pipe 6 AH050102050300 ---------- ----------
Snap Hose Assy 140507011001004530 140507011001005530 140507011001005530
24 3
JB1887-77 C-10X1W-450 C-10X1W-550 C-10X1W-550
Connector 10×
25 6
20
Joint Elbow AH1001020506 AH1001020506 AH1001020506
26 3
NPT1/4-M18×1.5
Connector AH1001020507 AH1001020507 AH1001020507
27 3 1
NPT /4-M18×1.5
28 3 Joint,90 AH1001020508 AH1001020508 AH1001020508
29 3 Piston rod clamp AH050102050600 AH080102050500 AH100102050500
30 3 Piston Rod AH0501020504 AH0801020503 AH1001020502
31 3 Liner
32 3 Liner End Cover AH0501010516 AH1001010520 AH1001010520

33 3 Locking Clip AH0501010517 AH1001010521 AH1001010521
34 3 Valve Guide AH050101051800 AH100101052200 AH100101052200
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
35 1 O-ring ---------- 420501010240600000 420501010240600000
T500-2005 T500-1020 T500-1027
36 18 Blot 3 7
/4-10UNC×2 /8-9UNC×13/4 7
/8-9UNC×2
37 1 Suction Manifold AH050101051900 AH080101050500 AH10010152300
38 Washer AH050101052000(4) AH080101050700(2) AH100101052400(4)
O-ring 530301012300070007 530301012900070007 530301013450070007
39 2
GB3452.1-82 230×7 290×7 345×7
40 Loctite 277 170506010100243000 170506010100243000 170506010100243000
41 1 Blind Flange AH050101010523 AH0801010508 AH1001010525
Bolt T500-1023 T500-1003 T500-1023
42 12
1-8UNC×31/2 7
/8-9UNC×31/2 1-8UNC×31/2
T501-1003 T501-1004 T501-1003
43 36 Nut 7
1-8UNC-2B /8-9UNC-2B 1-8UNC-2B
1
44 1 Pipe Plug NPT1 /2 T506-1007 T506-1004 T506-1007
45 1 Suction Flange AH0501020508 AH0801020506 AH1001020509
46 1 Suction Desurger
47 Washer 39 AH1001010527(18) AH1001010527 (24) AH1001010527 (24)
061401030500000000 061401030620000000
48 3 Hose Holder
2” 2 1/2”
T500-1009 T500-1025
49 12 Bolt 7
1-8UNC×3 /8-9UNC×3
T500-1024 T500-1026 T500 1024
50 12 Bolt 1 7 1
1-8UNC×4 /4 /8-9UNC×4 /4 1 8UNC 11/4
O-ring 530301011500070007 530301011850070007 530301011850070007
51 3
GB3452.1-82 150×7 (185×7) 185 7
52 3 Connector 450 AH0501020507 ---------- ----------
R1 12 Nut
R2 Nut
R3 Nut 11/2-8UN T501-2001 (24) T501-2001 (32)

F-500/800/1000DISCHARGE STRAINER &ACCESSORY’ MANIFOLD
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
1 1 Strainer Cap AH0501011401 AH1001021101 AH1001021101
O-ring 165×7 5303010116500700 5303010116500700 5303010116500700
2 1
GB3452.1-82 07 07 07
3 1 Strainer AH100101190200 AH100101190200 AH100101190200
4 1 Strainer Housing ----------
4A 1 Strainer Housing ---------- ----------
Pressure Gauge 3802071924025115 3802071924025115 3802071924025115
5 1 0-40Mpa 14 14 14
(YK-150)
Adapter NPT 3×11/2 T512-1002 T512-1001 T512-1001
6 1
R1 1/2XNPT3” R1 1/2XNPT2” R1 1/2XNPT2”
7 2 Elbow Assy NPT3 AH100101200100 AH100101200100 AH100101200100
8 1 Flange ---------- T508-1002 T508-1002
8A 1 Joint Pipe 4” AH05010119 ---------- ----------
9 1 Elbow Assembly AH0501021000 AH10010212 AH10010212
10 2 Pipe NPT3
T508-5001 T508-5002 T508-5002
11 Ring Gasket
R39 (2) R44 R44
Loctite(Lock + Tight) 1705060101002430 1705060101002770 1705060101002770
12 15ml 00 00 277 00 277
243
JA-3 Shear Relief AH0000060200 AH0000060100 AH0000060100
R1 1
Valve
Pulsation Dampener AK45350200 AK45350200 AK75350100
R2 1
KB-45 KB-45 (KB-75)
F-500 CROSSHEAD ASSEMBLY
ITEM
QTY DESCRIPTION PART NO
NO
1 1 Crosshead AH0501020401
2 1 Crosshead Guide AH0501020402
3 10 Capscrew 5/8-11UNCX1 1/2 T500-2004K
4 1 Diaphragn Stuffing Box AH0501010403
5 1 Crosshead Pin AH0501020403
6 1 Crosshead Pin Retainer AH0501020404
7 1 Fluid Baffle Disk AH0501010406
8 1 Fluid Baffle Back-up Plate AH0501010407
9 1 Locking Spring AH0501010408
10 1 Sealing Ring AH0501010409
11 1 O-ring 95X53.3 530301010950053007
12 1 Crosshead Extension AH0501010410
13 1 O-ring AH0501010411
14 1 O-ring 355X5.3 530301013550053007
15 8 Capscrew 1 1/4-7UNCX3 1/2 T500-3005
16 1 Adapter AH0501010412
17 2 Connector ø13xø22.5
18 1 Elbow AH0501010413
19 6 Capscrew 3/8-16UNCX3 1/4 T500-3002
20 1 Crosshead Bearing AH0501010414
21 2 Connector ø10xø20
22 1 Adapter NPT1/4-M18X1.5 AH1001020507
23 1 Plug NPT1/4 T506-1002
24 4 Wire ø1.6 040104030160001900
Snap Hose Assy C-13X1W-300
25 1 140507011301003030
GB1887-77
26 6 Locking Washer 10 420503011101600000
27 2 Double Lip Oil Seal AH0501010415
28 1 O-ring 71x5.3 530301010710053007
Snap Hose Assy C-10X1W-300
29 1 140507011001003030
GB1887-77
30 8.3ml Loctite 170506010100243000
31 1 Elbow Z1/4-M18X1.5 AH1001020506

F-800/1000 CROSSHEAD ASSEMBLY
ITEM PART No.

QTY DESCRIPTION
NO F-800 F-1000
1 1 Crosshead AH0801020401 AH1001020401
2 1 Crosshead Guide
AH0801010402 AH1001010402
(upper)
3 2 Capscrew T500-2015K T500-2018K
(3/4-10UNC×11/2) (1-8UNC×21/4)
4 Diaphragm Stuffing
1 AH0801010403 AH1001010403
Box
5 O-ring 530301011600035507 530301011750035507
1
(160×3.55) (175×3.55)
6 1 Sealing Ring AH0801010404 AH1001010404
7 1 Fluid Baffle Disk AH0801010405 AH1001010406
8 1 Crosshead Extension AH0801020402 AH1001010407
9 1 Crosshead Pin AH0801020403 AH1001020402
10 8 Capscrew T500-3014K T500-2019K
(3/4-10UNC×2) (1-IUNC21/2)
11 Crosshead Guide
1 AH0801010408 AH1001010409
(Lower)
12 8 Locking Spring AH0801020404 AH1001020403
13 O-ring 530301011280070007 530301011400070007
1
(128×7) (140×7)
14 4 Capscrew3/8-16UNC×1 T500-1021 T500-1021
15 1 Locking Spring AH0801010410 AH1001010411
16 1 O-ring 530301011030053007 530301011150053000
(103×5.3) (115×5.3)
17 8 Capscrew T500-3008 T500-3009
(5/8-11UNC×2) (3/4-10UNC×21/4)
18 8 Washer AH100101041700 AH100101041700
19 1 Plate Gasket AH0801010411 AH1001010413
20 1 Crosshead Pin Retainer AH0801020405 AH1001020404
21 1 Crosshead Bearing AH0801010413 AH1001010415
(4G254735Q) (5G254936Q)
22 2 Male Connector3/8 AH1001010405 AH1001010405
23 2 040104030160001900 040104030160001900
Wire 1.6
(L=400) (L=400)
24 2 Double Lip Seal AH0801010414 AH1001010416
4”x5”x0.5” 4.5”x5.5”x0.5”
25 2 040104030160001900 040104030160001900
Wire 1.6
(L=300) (L=300)
26 1 040104030160001900 040104030160001900
Wire 1.6
(L=500) (L=500)
27 4 Locking Washer 10
420503011101600000 420503011101600000
GB93-76
28 8.3ml Loctite(Lock+Tight)
170506010100243000 170506010100243000
242
F-500/800/1000 PINION SHAFT ASSEMBLY
ITEM PART NO.

QTY DESCRIPTION
NO F-500 F-800 F-1000
1 Key AH0501010301 AH0801010301 AH1001010301
1
1 1/4x1 1/4x7 1/2 1 3/4”x1 3/4”x8” 2”x2”x8”
2 1 Pinion Shaft AH0501020301 AH0801020301 AH1001020301
3 2 Oil Seal Wear Ring AH0501010303 AH0801010303 AH1001010303
4 2 Oil Seal Carrier AH0501020302 AH0801020302 AH1001020302
Oil Seal Carrier AH0501010305 AH0801010305 AH1001010305
5 2
Gasket
6 2 Gasket AH0501010306 AH0801010306 AH1001010306
7 2 Pinion Bearing AH0501020303 AH0801020303 AH1001020303
Gap Screw
8 3 5 3
T500-2003 T500-2003 T500-2003
/8-11UNC×1 /4
Locking Washer 16 4205030111616000 4205030111616000 4205030111616000
9 3
GB93-76 00 00 00
T500-1012 T500-1012 T500-1027
10 16 Cap Screw 3 3 7
/4-10UNC×2 /4-10UNC×2 /8-9UNC×2
Oil Seal AH0501010311 AH0801010311 AH1001010311
11 2
5.87X7.125X0.625 7.625x9.125x0.625 8.5x10.5x0.625
AH0501010312 AH0801010312 AH1001010312
12 2 Bearing
4G32828H 4G32836H 4G32840H
Locking Washer 4205030112016000 4205030112016000 4205030112216000
13 16
GB93-76 00 20 00 20 00 22
Locking Washer 14 4205030111416000 4205030111416000 4205030111416000
14 12
GB93-76 00 00 00
T500-1002 T500-1017 T500-1019
15 12 Cap Screw 1 1 1 1 1
/2-13UNC×1 /4 /2-13UNC×1 /2 /2-13UNC×13/8
16 1 Flange AH0501010313 AH1001010313 AH1001010313
F-500/800/1000 CRANKSHAFT ASSEMBLY
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
1 2 Main Bearing Cover AH050101020100 AH080101020100 AH100101020100
2 1 Bearing Carrier, Right AH0501020201 AH0801020201 AH1001020201
2 Gasket Main Brg. AH0501010203 AH0801010203 AH1001010203
3
Cover
4 2 Inner Race Retainer AH0501010204 AH0801010204 AH1001010204
5 3 Outer Race Retainer AH050101020500 AH080101020500 AH100101020500
6 3 Eccentric Strap AH0501020202 AH0801020202 AH1001020202
7 1 Inner Race Retainer (I) AH0501020203 AH0801020203 AH1001020203
8 1 Crankshaft AH050102020400 AH080102020400 AH100102020400
Inner Race Retainer AH0501020205 AH0801020205 AH1001020205
9 1
(II)
10 1 Eccentric Ring Gear AH0501010210 AH0801010210 AH1001010219
T500-2006 T500-2013 T500-2017
11 12 Capscrew 7
/8-9UNC×31/2 11/4-7UNC×4 11/4-7UNC×41/2
12 12 Locking Nut T501-301.00 T501-302.00 T501-302.00
7
/8-9UNC 11/4-7UNC 11/4-7UNC
13 2 Spacer, Main Bearing AH0501010211 AH0801010211 AH1001010211
14 1 Bearing Carrier, Left AH0501020206 AH0801020207 AH1001020206
15 2 Quter Race Retainer AH0501010213 AH0801010214 AH1001010213
16 2 Inner Race Retainer AH0501010214 AH0801010215 AH1001010214
T500-2002K (28) T500-1018K (72) T500-1018K (72)
17 Capscrew 5 1 5 1 5
/8-11UNC×1 /4 /8-11UNC×1 /2 /8-11UNC×11/2
1
Capscrew /2-13UNC× T500-2001K (24)
17A ---------- ----------
11/4
T500-1008 T500-1008 T500-1008
18 28 Capscrew
AH051020207 AH0801020206 AH1001010215
Housing Bolt Main AH050101021500 AH080101021200 AH100101021600
19 4
Bearing
20 Shim Set T500-2006 T500-2013 T500-2017
21 Outer Race Retainer T500-3004K (2) T500-3004K (2) T500-3004K (4)
T500-3001K T500-3006K
21A Capscrew 1 5 ----------
/2-13UNC×4 /8-11UNC×43/4
AH0501010216 AH0801010216 AH1001010217
22 3 Eccentric Bearing
92984QU 928/508QU 929/558.8QU
AH0501010217 AH0801010217 AH1001010218
23 2 Bearing
3053738U 3053748H 4053156H
Sealing Washers 16 4205010361602000 420501036160200 420501036160200
24 28
GB848-87 00 000 000
Loctite(Lock+Tight)2
25 90ml 170506010100243000 170506010100243000 170506010100243000
42
Safty Wire 1.5 0605010216000000 060501021600000 060501021600000
26 25m
GB343-82 00 000 000
Safty Wire 3 0605010212000000 060501021200000 060501021200000
27 1.6m
GB343-82 00 000 000
F-500 LUBRICATION ASSEMBLY
ITEM
NO
1 1 Manifold (1) AH0501010601
2 5 Pipe Plug NPT 1/4 T506-1002
3 2 Tbg Clamp (I) AH050102060100
4 1 Copper Tbg Assy. Ø10 051102010100010002
5 1 Male Connector 520901010330010010
6 1 Male Connector Elbow 520901010050010010
7 3 Tbg Clamp-Double Ø8 AH050102060200
8 1 Oil Pump Mtg. Plate AH050102060300
9 set Shim Set AH100101060400
10 1 2S Gear Pump 512601010031000000
11 1 Pipe Connector
12 1 Pressure Gauge (0~16Mpa)
13 3 Male Connector Elbow
14 2 Tube Union
15 2 Male Connector Elbow
16 2 Copper Tbg Assy. Ø12
18 7 Tbg Clamp 8
21 2 Oil Jet AH0501010603
22 4 Cap Screw 1/4-20UNCX3/8 T500-1007
23 4 Locking Washer 8 420503011081600000
24 2 Connector 520901010330020020
25 2 Connector T513-1007
26 2 Copper Tbg Assy. Ø8 051102010080010002
27 2 Copper Tbg Assy. Ø8 051102010080010002
28 12 Male Connector Elbow JB/ZQ4408-86 520901010330050050
29 1 Copper Tbg Assy. Ø8 051102010080010002
30 Tbg Clamp AH050102060500
31 2 Male Connector Elbow 520901010350040040
32 1 Copper Tbg Assy. Ø16 051102010160015002
33 2 Male Connector 520901010330040040
34 1 Oil Filter Assy. AH100101061000
35 2 Female Adapter Union AH1001010608
36 2 Copper Washer 520902551280120100
37 2 Tbg Clamp AH050102060600
38 1 Copper Tbg Assy. Ø16 GB1527-87 051102010160015002
39 1 Manifold ( ) AH1001010611
ITEM
NO
40 1 Male Connector(JB/ZQ4410-86) 520901010350050050

41 1 Relief Valve YYFJ-L20 512604900000032002
43 4 Cap Screw 5/16-18UNCX1 5/8 T500-3003
44 4 Locking Washer(GB93-76) 420503011081600000
49 Copper Tbg Assy. Ø8 GB1527-87 051102010080010002
50 2 Male Connector Elbow T511-3003
51 2 Key 4.76X4.76X25.4 T516-2001
52 2 Oil Pump Gear Assy. AH050102060700
53 2 Copper Washer
54 4 Washer 6
F-800/1000 LUBRICATION ASSEMBLY
ITEM PART NO
QTY DESCRIPTION
NO F-800 F-1000
4 Tbg Clamp (I) AH050102060100 AH050102060100
Cooper Tbg Assy 10 051102010100010003 051102010100010002
2 1
1143 1270
3 1 Connector JB/ZQ4408-86 520901010330010010 520901010050010010
Tbg Clamp-Double 8
4 AH050102060200(2) AH050102060200 3
5 1 Oil Pump Mtg Plate AH080102060300 AH100102060100

6 Set Shim Set AH100101060400 AH100101060400
7 1 Oil Pump 512601010031000000 512601010031000000
8 1 Connector NPT1/8 T001-0401 T001-0401
0-1.5MPa
Pressure Gauge<M14×1.5>
9 1 380202051160006021 380202050060006020
(Y60-Z)
10 Connector Elbow T001-2202 T001-2203
Connector 520901010050050050 520901010050050050
11 2
Connector Elbow 520901010330020020 520901010330020020

12 2
Copper Tbg Assy 12 051102010120010002 051102010120010002

13 2
787 630
Copper Tbg Assy 8 051102010080010002 051102010080010002
14 2
889 966
Tbg Clamp 8 AH050102060400 AH050102060400
15
(14) (13)
Copper Tbg Assy 12 051102010120010002 051102010120010002
16 2
890 230
17 2 Oil Jet AH0801010601 AH1001010606
Capscrew 1/4-20UNC
18 4 3 T500-1007 T500-1007
/4
Locking Washer 8 420503011081600000 420503011081600000
19 8
Copper Tbg Assy 8 051102010080010002 051102010080010002
20
(1) 254 (2) 305
Copper Tbg Assy 8 051102010080010002 051102010080010002
21 1
711 (838)
Copper Tbg Assy 8 051102010080010002 051102010080010002
22 1
1295 (584)
Copper Tbg Assy 8 051102010080010002 051102010080010002
23 1
432 (940)
Copper Tbg Assy 8 051102010080010002 051102010080010002
24 1
(890) (1016)
25 1 Copper Tbg Assy 8
ITEM PART NO
QTY DESCRIPTION
NO F-800 F-1000
1
26 5 Pipe Plug NPT /4 T506-1002 T506-1003
27 1 Manifold (I) AH1001010607 AH1001010607
Copper Tbg Assy 8 051102010080010002 051102010080010002
28 1
508 153
Copper Tbg Assy 8 051102010080010002 051102010080010002
29 1
610 737
30 Loctite 609 170506010100609000 170506010100609000
Copper Tbg Assy 8 051102010080010002 051102010080010002
31 1
1016 661
32 2 Connector 450 AH1001010608
33 2 Connector Elbow
34 2 Connector Elbow
Copper Tbg Assy 16 051102010160015002 051102010160015002
35 1
330 331
Copper Tbg Assy 16 051102010160015002 051102010160015002
36 1
635 686
37 1 Copper washer14
38 2 Tbg Clamp-triple 8 AH080102060200 AH080102060200
39 2 Connector Washer 520902551280120100
40 1 Oil Filter Assy AH100101061000 AH100101061000
Connector 520901010330040040 520901010330040040
41 2
Connector Elbow 520901010350050050 520901010350050050
42
(3) 12
Connector 520901010330050050 520901010330050050
43 5
17 5
44 1 Manifold (II) AH1001010611 AH1001010611
45 1 Relief Valve 512604900000032002 512604010001202000
Capscrew 5/16-18UNC
46 4 T500-3003 T500-3003
15/8
Copper Tbg Assy 8 051102010080010002 051102010080010002
47 1
1295 1651
48 1 Oil Pump Gear Assy AH080102060100 AH080102060100
49 1 Key 4.76 4.76 25.4 T516-2001 T516-2001
Copper Tbg Assy 8 051102010080010002 051102010080010002
50 1
965 1016
Copper Tbg Assy 8 051102010080010002 051102010080010002
51 1
203 267
Copper Tbg Assy 8 051102010080010002 051102010080010002
52 1
1295 1372
53 1 Copper Tbg Assy 8 051102010080010002 051102010080010002
ITEM PART NO
QTY DESCRIPTION
NO F-800 F-1000
1804 2007
Connector Elbow 520901010330010010 520901010330010010
54 2
Copper Tbg Assy 051102010100010002 051102010100010002
55 1
10 1448 1651
F-500/800/1000 PISTON & LINER WASH
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
AH050101080300 AH080101080200 AH100102080100
1 1 Belt Guard
AH050101080500 AH080101080800 AH100102080400
2 1 Sheave AH0501010801 AH0801010801 AH1001010802
3 1 Support Gassy AH050102080100 AH050102080100 AH100102080200
4 1 Elbow NPT1-G1 AH1001010804 AH1001010804 AH1001010804
5 Connector NPT1 ---------- ---------- AH1001010805 1
Connector NPT1-M33 AH100101051805 AH100101051805 AH100101051805
5A
2 3 (3) 1
Connector G1-M33
6 1 AH1001010806 AH1001010806 AH1001010806
2
7 Connector ZG21/2 ---------- ---------- AH1001010807 1
Connector
8 ---------- ---------- AH1001010808 1
ZG21/2-NPT21/2
1405010102201000 1405010102201000 1405010102201000
9 Hose 22 37
00 00 00
Connector 22
10 AH100101080900 (4) AH100101080900 (4) AH100101080900 2
37
11 3 Elbow NPT 1 900 AH1001010810 AH1001010810 AH1001010810
12 2 Connection Plate AH0801020801 AH0801020801 AH1001020803
13 1 Tank AH080101080400 AH080101080400 AH100101081200
14 1 Tank Cover AH080101080300 AH080101080300 AH100101081300
5
15 8 Nut /8-11UNC T501-1002 T501-1002 T501-1002
16 2 Washer AH1001010814 AH1001010814 AH1001010814
17 2 Flange NPT1 AH1001010815 AH1001010815 AH1001010815
Locking Capscrew 4201030283080025 4201030283080025 4201030283080025
18 2
(GB73-85) 00 00 00
1403010120274300 1403010120340400 1403010120315000
19 2 V belt(GB1171-74) 00 00 00
A2743 A3404 A3150
0614010103800000
20 2 Pipe Clamp NO.3 ---------- ----------
00
1405010103803053
1405010102201000 1405010102201000
21 1 Hose 00
00 22 37 00 22 37
38 53
5202070504006500
22 1 Elbow 900 ZG21/2 ---------- ----------
02
5
Capscrew /8-11UNC
23 8 T500-1011 T500-1011 T500-1011
2
Locking Washer 16 4205030111616000 4205030111616000 4205030111616000
24 8
(GB93-87) 00 00 00
ITEM PART NO
QTY DESCRIPTION
NO F-500 F-800 F-1000
4205010601601000 4205010601601000 4205010601601000
25 Washer 16(GB95-86)
00 00 00
1
Capscrew /2-13UNC
26 4 T500-1004 T500-1004 T500-1004
15/8
Locking Washer 14 4205030111416000 4205030111416000 4205030111416000
27 12
(GB93-87) 00 00 00
4205010601201000 4205010601201000 4205010601201000
28 4 Washer 12(GB95-86)
00 00 00
1
Capscrew /2-13UNC
29 8 T500-1005 T500-1005 T500-1005
21/4
30 8 Nut1/2-13UNC T501-1001 T501-1001 T501-1001
31 1 Pump AH100101081600 AH100101081600 AH100101081600
G1 Globe Valve 4413050111041610 4413050111041610 5127043000240702
32 1
(Q11F-16) 25 25 50
33 1 Pump Support AH050102080200 AH080102080200 AH100101081700
1
34 1 Connector NPT2 /2 T513-1004 T513-1004 T513-1004
T506-1006 (5) T506-1006 (3)
R1 1 Pipe Plug
NPT1 NPT1
F-500/800/1000 TOOL LIST
ITE PART NO.

QT
M DESCRIPTION
Y F-500 F-800 F-1000
NO
1 1 Cylinder Head Plug Tool
2 1 Seat Lifting Tool AH050101150300 AH100101210600 AH100101210600
3 1 Charging Hose AH10010213010 AH100102130100 AH100102130100
Manual Hydraulic PUMP 5126050400001170 5126050400001170 5126050400001170
4 1
70Mpa PSH-II 00 00 00
F-500/800/1000 SPARE PARTS LIST
ITE PART NO.

QT
M DESCRIPTION
Y F-500 F-800 F-1000
NO
1 3 Oil Seal AH0501010508 AH1001010508 AH1001010508
2 6 Oil Seal AH0501010504 AH1001010504 AH1001010504
3 3 O-ring 44 ---------- T508-5002 T508-5002
4 2 Seal Washer AH10010109 AH10010109 AH10010109
5 3 Sealing Ring AH0501010409 AH0801010404 AH1001010404
6 O-ring 39 T508-5001 3 T508-5001 (1) T508-5001 1
7 1 Buffer AH0000060106 AH0000060106 AH0000060106
8 1 Bladder AK4535010100 AK4535010100 AK7535010200
9 3 Locking Clip AH0501010517 AH1001010519 AH1001010519
SECTION 3
KB-45/75 PULSATION DAMPENER
PARTS BOOK AND DRAWING LIST
DESCRIPTION PART NO. PAGE
KB-45/75 Pulsation Dampener AK45350200/ AK75350200 90
Pulsation Dampener AH100102130100 93
Charging Hose &
nstructions
KB45/75 PULSATION DAMPENER
ITEM PART NO
QTY DESCRIPTION
NO KB-45 KB-75
1 1 Sealing Ring 39 T508-5001 T508-5001
2 1 Bottom Plug AK75350101 AK75350101
3 1 Bladder AK4535010100 AK7535010200
4 1 Studded Assembly AK4535020100 AK7535020100
5 1 Head AK45350103 AK75350202
6 1 Steel Pipe Tee1/4 AK75350105 AK75350105
7 1 Close Nipple1/4 AK75350106 AK75350106
8 1 Gauge Cover AK4535010400 AK7535020300
9 1 Purge Valve(PTC1-L8) 512604900000030801 512604900000030801
Pressure Gauge
10 1 380101052250006021 380101052250006021
O-25Mpa (Y-60)
Needle Valve 1/4
11 1 512604900000020801 512604900000020801
12 1 Sealing Washer T514-1001 T514-1001
PULSATION DAMPENER CHARGING HOSE & INSTRUCTIONS
ITEM
QTY DESCRIPTION PART NO.
NO.
1 1 Nut AH100102120101
2 1 Sealing Connector AH100102120102
Hose M14 1.5
3 1 520901050030080084
4 1 Connector AH100101210703
5 1 Gasket AH100101210704
6 1 Pipe Plug AH100101210705
CHARGING INSTRUCTIONS
1.Remove dampener gauge cover. Bleed off any existing pressure in gage area by
turning purge valve cap approximately 1/4 to 1/2 turn. Remove purge valve.
2.Connect charging hose to dampener charging valve and nitrogen cylinder valve.
3.Open dampener charging valve.
4.Open cylinder valve slowly. Use this valve to regulate flow to dampener.
5.When dampener gauge shows desired charging pressure, close cylinder valve.
6.Close dampener valve.
7.Remove hose from dampener charging valve and replace gage cover.
For best results. dampener precharge pressure should be not more than 2/3 of pump
discharge pressure. Maximum precharge 650 PSI.
CAUTION: USE ONLY COMPRESSED NITROGEN OR AIR---DO NOT

CHARGE WITH OXYGEN.
SECTION 4
JA-3 SHEAR RELIEF VALVE

PARTS BOOK & DRAWING LIST
DESCRIPTION PART NO. PAGE
JA-3 SHEAR RELIEF VALVE AH0000060200 96

JA-3 SHEAR RELIEF VALVE
ITEM
QTY DESCRIPTION PART NO.
NO.
1 1 Adapter Bushing AH0000060101
2 1 Plain Washer AH0000060102
3 1 Plunger Seal AH0000060103
4 1 Body AH0000060104
5 1 Plunger Stem AH0000060105
6 1 Bumper AH0000060106
7 1 Roll Pin AH0000060107
8 1 Cover Spring AH0000060108
9 1 Cover AH0000060109
10 1 Shear Bar AH0000060110
11 1 Shear Pin AH0000060111
12 1 Warning Plate AH0000060112
13 1 Shear Bar Pin AH0000060113
14 2 Retainer Ring AH0000060114
15 1 Name Plate AH0000060115
16 1 Cotter Pin 4 26 420703020504002600
17 2 Nut M4 420402080040200000
18 2 Capscrew M4 16 420101021104001600
19 1 Bolt 3/8-16UNC 41/4 420201070710110010
20 1 Nut 3/8-16UNC 420402080100200000
21 4 Capscrew M3 8 (GB67-86) 420101020703000800

Bomco F-500 800 1000 Manual

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Bomco F-500 800 1000 Manual

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Available Formats

OPERATION AND MAINTENANCE

MODEL : F-500/800/1000 TRIPLEX PUMP

& MAINTENANCE MANUAL

2 F-500/800/1000 TRIPLEX PUMP PARTS BOOK

3 KB-45/75 PULSATION DAMPENER PARTS BOOK

4 JA-3 SHEAR RELIEF VALVE PARTS BOOK

2.INSTALLATION OF NEW PUMP 12

7.EXPLAINS FOR ORDER……………………………………………………………….66

F-500 F-800 F-1000

model F-500 F-800 F-1000

1 0.1262 0.915 0.1683 0.1466 0.1264 0.1077 0.0905 0.0748

NOTE:1.Based on 100% volumentric efficiency and 90% mechanical efficiency

2. Recommended speed and input horsepower for continous service

HORSEPOWE LINER SIZE (mm) AND PRESSURE RATING( Mpa.kgf/cm2)

1 0.2594 0.2298 0.2020 0.1759 0.1517 0.1293 0.1086 0.0898

NOTE:1.Based on 100% volumentric efficiency and 90% mechanical efficiency

2. Recommended speed and input horsepower for continous service

LINER SIZE (mm) AND PRESSURE RATING( Mpa.kgf/cm2)

1 0.2883 0.2553 0.2244 0.1955 0.1686 0.1436 0.1207

NOTE:1.Based on 100% volumentric efficiency and 90% mechanical efficiency

2. Recommended speed and input horsepower for continous service

In order to prevent personal injury during the performance

2.1 Setting The Pump

2.2 Land Installations

2.3 Permanent Installations

2.4 Installation Of The Drive

Pump Type Hub Torque Length N

F-500 N 406 760 534

F-800 P 610 760 800

F-1000 W 813 900 900

2.4.1 V-Belt Drives

a. Check sheave groove condition.

b. Check sheave alignment.

c. Adjust V-belt for proper tension

DO NOT OBTAIN BELT TENSION BY PICKING UP END OF PUMP AND

b. Drive chain lubrication

REFER TO GENERAL LUBRICATION BULLETIN for approved lubricants and

2..6 Power End

2.6.1 Power End Lubrication

Fit oil pipe (6)

d. Install the lock spring (10).

F-800 16 24 N·m (12 18 ft·lbs)

SEE NOTE BELOW

c. Install the O-ring (8)in groove in stuffing box bore.

SEE NOTE BELOW

e. Install the lock spring (9)

Stationary spray type have been used on BS F-series pumps Ref.

2.8 Fluid End Assembly

2.8.1 Valves and seats

F-500, F-800, F-1000 ASSEMBLY OF FLUID END PARTS

2.8.3 Piston Rod

F-500 500 N m (368 ft lbs)

2.8.4 Piston Rod Clamps

2.8.5 Liner Cage and Lower Valve Guide

2.8.6 Cylinder Head

2.8.7 Discharge Valve Pot Covers

2.8.8 Discharge Manifold all Models

2.8.9 Suction Flange

2.9 Accessory Manifold

3.3 Total Pressure Lubrication System