zo0seas ——_|GRITIOO. ‘3019610 [OUIDE RING POS. 4 3 [pza ‘Sor1eu6 GASKET POS. 3 (SAP AUST) 3 —eza 240se67 ——[orrTico. 017144 RING GRONCE NNER @ 111 mm POS. (SAP ZOIDTOG) 3 fean. 2008026 ——ERITICO 18011668 DELIVERY DIAPHRAGM, COMPIL, POS. 11, POS. + ‘3 Joza [pameses| 2305388 joririco 5032133 [DELIVERY OIAPHRAGI, COMPIL, (REP) 3020138 JPTURE FOR GUIDE BUSHING cana 2asre —— [oT 504177 [VALVE CONE 3px eS 2a0s019 [ALA ROTA DY 194 VALVE PLATE oer DRAWING te 22050596 ALTA ROTACION i 3011660 VALVE SEAT 6 [Pca Tes 2047 [ALTAROTACN| 206 [VALVe SEAT RECUDERADO] Boze eos TA ROTACDN $o20544 [SHAFT SEALING RING 4 2000505 OSTEO i aza imeses | CeawmG ie a205 [oRsiGo A TPESOO7D7E i DRAWING NF 270S%9e [oRTICD. ‘025139 |VALVE COVER SEAL ACC. TO ORWG 2105609 FOS. 70 sea 2406886 ——_[eRITICO. 8136 SEAL 0771 007A0 01 (UTEX (9084409) sez DRAWING te 20D THOSE RT: s020136 Jouibe auSeING 3 za zs0as33— [oRITICO. 1 1s 70a | SEAL Wh CONG PROFLE RITA ROTTS BOSETT aa pea OTT ——[SRTEO 3020134 |VALVE COVER SEAL ACC.TO ORWG 2100070 POS. 3 3 PzR DRAWING 2406878 [GRITICO 241 NUT FOR VALVE. Span. “oaa28 JSR. G01 684 ROUND PACKING RING T60KA_ SORT SHORE Pea DRAWING WY 2TRDRE|GRITCO. ‘ORAS [FLAT-NPE SEAL SATS. Zo, 17357 [FLAT SEAL (COVER CRANKSHAFT BEARING) 2 ENG FATT [077355 |FLAT SeaL (SEARING HOUSING CRATHCSHAFT = [=o Toei 2201075 8044744 [PRESSURE VALVE HOUSING APIO. Jum, 2305582 GOIGYEE [PRESSURE VALVE HOUSING API (REF) jum ‘9032151 JOMAPHRAGH HOUSING (REP) 3 15020083 JAPHRAGI HOUSING 3 ae 7 ‘a2 |DIAPLIRAGH HOUSING COVER [REF] fom ‘9016571 OAPHRAGH HOUSING COVER (10zT02T-TOOERE7] Sean OSE ‘9030055 SUCTION CONWECTION Pr 3 ran 210555 ‘022127 |SUCTION CONNECTION PlecE [REP] fom ‘3028243 |SUCTION VALVE HOUSING APT 3 ran BE 1502134 [SUCTION VALVE HOUSING APIS (REPT fun, 026286 [SUCTION VALVE HOUSING API (REF) fun ostn62 ADAPTER (11071025 ia ZOE ‘01546 [STOP BALL COCK BK DN=HO (DESFOGUE ACEITE APL 3 fee. 16227 Goz61a0 VL SCREW Mi0Z0.ON G12, 6 STANLESS STEEL GOTTDOH, Baeza DG 3308387 18012882 [PISTON SEAL KIT POS. [SAP 2101138 ‘sea ‘ras “3011879 [DOUBLE FILTER TYPE 25Ds0GaOR MOSIGE 11am Pauneed ‘OTIvTE SEN. RO 206/160 9 APN 3S aa. eras ‘9011310 ROUND PACKING RING 108.257 -NBR™60 SHORE'A POS. 3 este ‘9011540 FLOW INDICATOR WN#260-11-CU2N. Pea, oeves10 ‘913917 SEALING ING DIN 7e0S C47 x23 CURA. 3 fren 21ST SOTH771 [PRESSURE SPRING [SPRING PRESSURE FOR VALVE] Pea 2 ‘10024 NOV TURN VALVE RVAGN INSTI - 12" (VALVE RON RETR TE 3a. FEE Gojetad JaSNG FIXTURE GOTT) Shea Basra 1021623 JNOVO THAR GROGVED RING T20- 1102150 (031602) 3 fea 206678. 021657 ORT SORAPER PO 110% 127.2542 3 een. 15258 90502 SER COVER 039026) 3 Zeca? [oaInco : 02264 NTA ESPROWE ALIGR DE @SSOUPSL a {029966 JUNTA ESPROWETALIGR DE B60 PSL 30 Jun 030610 INT A ESPROWETALIGA DE 4x 1500 PST 0 5099007 |RETEN CR-99700 BOMBA WIRTH [SYNCHROORVE) 2 lea 3055801 [GUAD RING SEALS 30a, ‘0ssa02 JOUTER CAVITY GASKET 70 — [oN ‘5057441 [SEAL [DETRAS De PORTA DAFRAGI 2 [on TTT TOOT ‘9055657 |RODAMIENTO 73228 Yu WSS C3 [eo ow, 15050055 [RODAMIENTO 22922 EASM Et C3 eto) [oN Goa007 JRETEN V= ve VA~ Tab (REDUCTOR) st ma 034008 JRETEN V- RIUG-VA-08 (REDUCTOR) 20st A 5030645 JOAPHRAGH BFA 7016040 POS. 8 Jone "osze7 "2081604 [ROUND PACKIN RING 140 X3 POS. 6 3 Jon 005 14a 1011006 FLOW MIOICATORWZ6GID SIZE ¥ WiRTHREGUA + ‘9051602 [NOVOTHAN GROOVED RING 120110 X 130 POS. B 3 Jon aT ‘cosi603 [DIRT ScRAPER Pa 100 K1722% 12 POS. 7 3 Jun ‘2oaesis4 "908458 ‘COVER SEAL ACG. TO ORWG 2UREUBU POS. 7 GOSETIOL 3 ‘aoe /9034e01 [SEAL o771-70074001 ( UTEX] POS. 3 200160 9033826 [INSERT COVER POS. 18 ‘jun "200567 = ‘2011802 [CvL, SCREW 46x20 OIN S125, 6 STANLESS STEEL POS.27 az “200067 ‘S011515 [BUSHING FOTURE Pos. 25 (SAP 20260785) 3 jun 2204420 004424 [LINER POS. 7 unr 2505021 ‘2026 [CYLINDER SCREW OR TSU 5, STEEL POS. [uN 'S0ai26 TOOTHED LOCK WASHER AZ1-DIN 6787 5.5 POS. 4 [unr 9034427 DIAPHRAGN GUIDE ROD POS. 6 = unr 0a ‘30a44z8 VALVE HOUSING Pos. 2 3 Joe 204886 19044402 |SAFETY VALVE NG 10 POS.@ 4 — Tow, ‘SRDER a1a0. ‘5034405 CONNECTION PIECE POS. 22 fo, TEVLS12 0KO-AIT 034404 JREDUGING FITTING POS. 3 3 Jon RED 20/12 78436 5034405 [STRAIGHT SCREWNG ON POS. 3 7 ow, ‘GAL 20.78RAIC 5034406 SEALING RING POS. 37 Jum, TIN 7ons-a77s2-00 [SEALING RING DIN re0s.c17<25-GuFa POS. ‘3 — [uw s1008 9084305 [BEARING BUSH (8082739) = Jun eases7208626 3012510 [GUIDE RING POS. 4 = icra. | 3011695 jonsKer Pos. s (SAP 20385597), seat 2408067 ——Jerrrico, 15049144 [RING BRONCE NNER 9 411 mm POS. 8 (SAP 257 3 ran aos RICO. 3011609 [DELIVERY DIAPHRAGM, COMPIL, POS. 11, POS. 1 ‘3 Jrza [pt mEsES| —— 2308366 ferric ‘5032133 [DELIVERY DIAPHRAGM, COMPIL. [REP] 526138 [FIXTURE FOR GUIDE BUSHING cm TasTe ears 9012104 VALVE PLATE ~ DRAWING iP 220R00 ALTA ROTACION So11e80 |vacve Sear eo feza as ZiodazT——— [ALTAROTACION S01 2ate VAL Ser RECPERADD|— 5 [ez | tenis: [ALTA ROTACION| 6020644 GHAMT SEALING RING A 200305 ON STET 5 oca |EMeses | DRAWN ENTE feo 0020085 FORAEDA VIRING ORDER N* BS002 924453 = ez DRAWING RY 22099S JORTICO- ‘020130 |VALVE COVER SEAL ACC. To ORWG 2105800 POE. 20 fren. 710689 ———[GRITICO. Tass [SEAL O7/17c-o7an% (UEX) (ooaeant) Sez SRN N° 2007 SOBE[GRITICO 5020136 JGUIDE BUSFANG 3 fee, Zandsss— [oRITICO. Go 704 [SEAL Wh CONG PROFLE B27 ROTH as RETA 3a Pea, 20256187 —— FORT 9025184 |VALVE COVER SEAL ACC. TO ORWG 2406076 POS. 3 3 |RaA. ‘DRAWING 2400579 [GRITICO y52e1 NUT FOR VALVE. 6 Pea, za0aa26 ——[oRITCD 6011654 [ROUND PACKING RING 150K BO STSHORE a een, DRAWING NY 270RDRE|SRITICD. eroaaTe [SELF ALIGNING ROLLER BEARING 25360 K COON ESS 2 [on 2diGs FLAT-TYPE SEAL B POSRATOS a ‘1357 FLAT SEAL (COV GRANGHAPT BEARIIE] ow, DRG TATE 011365 FLAT SEAL (BEARING HOUSING CRANKSHAFT 2 fon, DW 2401675 Go1d4744 PRESSURE VALVE HOUSING APL fam, 2305392 3016168 [PRESSURE VALVE HOUSING API [REP] fam 30321 [DIAPHIVGIA HOUSING (REP) fom, 5030085 OMPHRAGM HOUSING 3 fra ase ‘9082422 [DIAPHRAGH HOUSING COVER (REPL fom. "8016071 [DIAPHRAGM HOUSING COVER {11020ZT-080E7] fen, ‘oer 080088 [SUCTION CONNECTION PIECE. 3 ran 210966 IE ‘9082137 [SUCTION CONNECTION PIECE [REF] — tow 19025245 [SUCTION VALVE HOUSING APTS fea SEI ‘8002484 [SUCTION VALVE HOUSING APs [REP] fom ‘8025206 [SUCTION VALVE HOUSING API (REP] Jum 0062 [ADAPTER [FIC0=8) ea, THSEL ‘3015146 [STOP BALL COCK 6K Oi=70 (DESFOGUE ACEITE AP) 2 1627 Gozetan [eve SexeW Mi0a0 Gotz 6 STAN ESS STEEL GOTISER) Za eza DHE eee ‘913862 PISTON SEAL KFT POS. 3 (SAP 2VOTT3A6) ‘rea. 2407437 011075 DOUBLE FILTER TYBE 25D00HOR MOISE: aren ase OUT10T5 [SEAL #0 2Ri66x2, APM 98 arm Spats 5011318 [ROUND PACKING RING 109. x67 -NER 60 SHORE AROS. 16 3 [Pea es 723401 [BUSHING FOR VALVE CLOSURE POS. 22 3 rea. 205429 'SOTTGT7 [SEALING RING DIN 7603 C17 923 COPA 3 Pea, 2oo1stee [GoHI77T [Pressure SPR (SPRING PRESSURE FOR VALVE] iz an, : BOs [NON RETURN VALVE REWV2BMIXG12 12" (VALVE NOW RETURN IZ] cama Pei GozeTas [SUSU FXTURE (OTT3Te) Sea. usr 011221 [ROUND PRGKING RING 160.215 70-WAR=00 SHOREAPOEAT a Raves 15021675 JNOVOTHAN GROGVED RING T20- 1101 130 (9037602) seen 2o1es78 Go2i657 [ORT SCRAPERS 110x122 97 3 [pea 5.958 SoaOtO2 [MER COVE (oos3e28) seen aos? STE [9057264 LSUNTA ESPIROUETALICA DE #9300 PSL io [on 9032755 LUNTA ESPIROMETALICA DE 62500 PST a0 on = [9032750 LUNTA ESPIROME TALIA De 8150 PSL =o [ON 053610 LUNA ESPIROMETALICA De © 1500 PST 0 5032002 [RE TEN CR 25700 BOMEDA WRT (SYNCRODATE) pmaZs ESTs 9055901 [GUAD RING SEALS 73a [ont 9048802 JOUTER CAVITY GASKET 00 — [UN Gosz141 [SEAL (DeTRAS be. PCITA DIAFRAGAIY fox TOON, 5003857 [RODAMIENTO 25028 VM WS3 C3 real 4 5053258 [ROOAMIENTO 22520 EAS E13 frst 4 809.007 JRETEN V- FING VA “140 (REDUCTOR) 4 ae 34308 IRETEN'Y= RING VA-05 REDUCTOR) z [va 19030648 DAPHRNGN BFA 7080-40 POS, z 2108957 1031604 JROUND PACKIN ING 1403 FOS. 3 posst4e2 19011506 |FLOW INOICATORIZSVO SIZE 1 WiRTH REBULE o 1903602 JNOVOTHAN GROOVED FING T20 110X199 POS. x ons8195 9031605 [DIRT SCRAPER PG -100.x 1222 12 POS. 3 2o2set04 9031367 |DAPHRAGH COVER SEAL ACC. TO DRWG 2105589 FOS 7 BOSTTID) = 0568 0ad4os SEAL 0771.700740.01 (UTEX) POS. 9. = si60 0s25 ‘COVER POS. 18 3 203587 ‘9011002 CYL, SCREW Wi0xz0 ONL S125, 0 STANLESS STEEL POS-2T iz 71000673 ‘011315 [BUSHING FIXTURE Pos. 25 (SAP 20260785) = 2204420, ‘9025516 |O.RING 34.00 x 300~05 FKM S92 POS. 5 = ossizeo ‘994424 JURER POS. 7 = 2308521 ‘Soa442s JEYLINDER SCREW DN BI-WaDxa0 S:STEEL FOS. 3 19034428 [TOOTHED LOCK WASHER AZ-DIN 6787 8.5 POS. 4 2 3oa4427 [DAPHRAGH GUIDE ROO POS.6 3 ore ‘04428 [VALVE HOUSING Fos. 2 2 20886 034402 SAFETY VALVE NG 10 POS. + ‘ORDER 442007. ‘094405 [CONNECTION PIECE POS, 22 % TEVLS12.0KORE 034404 REDUCING FITTING POS. 36 3 RED 20225430 S054H06 [STRAIGHT SCREWING ON POS.3E 7 [om “GALZZSRAIC 034406 [SEALING RING POS. 97 [un TIN TeD5-A27x2-0T 9034407 [SEALING RING DIN 7600.1 7e25-GoFa POSE To es1006 9031305 [BEARING BUSH (0032130) i 2406886rr Sheet 1 Drawing No. WIRTH List of Contents of : enone 72 2407124e Designation: TPM 8" x 10" Customer: Falconbridge, Ontario / Canada File No.: 86.120.00 - 99 No. Object Drawing No. 4 Pump unit - main dimensions 2102044 2 General information 2406204 Safety instructions 2406205 3 Technical details 2407125 Operating manual: 2407126 4 - Technical description - Operating instruction - Maintenance instruction - Repair instruction 5 Maintenance scheme 2001409 Lubrication chart 2407130 6 Total assembly 2101984 Pump TPM 8" x 10" z Gearing 2001317 8 Gearing frame 2305353 Protecting hood 2101647 Driving shaft 246 luce 2203190 8 Crankshaft peel 2201876 Connecting rod bac‘ 2203150 Crosshead crsctle 2304656 10 Crosshead rod stuffing box 2405958 Clamping piece 2404878 “ Driving liquid piston 2305378 2 Lubrication and cooling system (scheme) 2305550 Lubrication and cooling system 2001319 Electric gear pump 13 Pressure relief valve Duplex filter Flow switch Level switch ‘Suction strainer (filter) 44 Fluid end 2001306 ra1dap2efermico. 9012810 [OUDE RING POS.4 3 pz 2208026 5011605 [GASKET POS. 3 (SAP ETE) 3 pzn ‘2avs507 ——forrmico. 5012144 [RIG BRONGE MINER 111 mi POS. [SAP ZO2SeT0) 3 pan 2406625 JerITICo. ‘9017888 [DELIVERY DIAPHRAGH COMPIL POS.11, POS. 3 [pan |x MESES] ——sansas8 ——|enrrico ‘3002153 [DELIVERY OAPHRAGI, COMPIL [REP] 028135 [FAURE Fore GUE BUSHING IR era _—— [ea O1167? VALVE CORE fora | ES 22901 ALTA ROTA 901690 [VALVE SEAT [Pen | TODS Zor LTAROTACNT 2012406 [VALVE SEAT RECOPERADD) open ens [ALTA RGTACON| 00684 SHAFT SEALING RING A 200X200K5 DNB “za |S WeSeS | ORRIN Te ZATETEE JoeTiCo. 125045 |FORFIEDA VAING ORDER Nv 002024455, 7px BRAWN Re zanstoe JereTica ‘9025130 VALVE COVER SEAL AGG. TO DAWG 7405609 FOS. 25 3a, 205598 _—_—_[ERITICO. ‘gatas |SeAL 0771-70.07405 (UTEX (9088804) 3 pee DRAWING we 200TSRHEJORITICO. ‘00136 [ooibe BUSHING 3 [een 2500633 [eRITICO. 04704 SEAL WIT CONG PROFLE BETA ROTTS CORTE aa fee | — 2256 167 — Ric ‘Goa1a4 [VALVE COVER SEAL ACC. TO ORWG 2106879 POS. 2 ‘3 fren DRAWING 200657a|eATTICO Sois241 [NUT FOR VALVE Pen 73078 ———[oRITICo D1 1604 JROUND PACKING RING 160, CHT SRORE, Tappan. [BRAVING Re ZARDARI CRTICD ozdora [SELF ALIGNING ROLLER BEARING 25260 KC DES 2 TAT-TYPE SEAL 8 72508 z LAT SEAL (COVER CRANKSHAFT BEARS) — z TawS HES FLATSEAC Bens HOUSING CRANKS APT) z ‘DRIWG: 2401075 = PRESSURE VALVE HOUSING API = 2505892 [PRESSURE VALVE HOUSING APIO (REP 3 lDPHRAGH ROUSING (REF) = IAPHRAGH HOUSING. 2 ois [OIABHRAGH HOUSING COVER REP 2 [DIAPHRAGH HOUSING COVER 11027021 7005087) = ives [SUCTION CONNECTION PIECE 3 210966 [sucTioN CONNECTION PIECE [REF] son [SUCTION VALVE HOUSING API's z BO [SUCTION VALVE HOUSING APL a REP) —— 3 ow [SUCTION VALVE HOUsING API (REF) 3— [unr ADAPTER coziao9) Pox ‘Sois14s [STOP BALL COCK BK DHEZO (DESFOOUE AGEITE AP] 2 Go2B140 JOVL SCREW Wilkad ONUIZE. c STANNESS STECL (OOTTBO2] aa fron Dae 250507 501882 [PISTON SEAL KIT POS. 3 (AP 210T1S35) 6 |zn 2207457 0011679 JOOUBLE FILTER TYPE 25D90GaIR MOIG™ een poset SOrTOTE [SEAL RD 20865 x2. AFIT 22 3 ez Brag a 3011318 ROUND PACKING RING 108.2 <8.7-NBR- 90 SHORE APOS. 16 saa azz 19029161 [BUSHING FOR VALVE CLOSURE POS. 22 3px Bans 1011810 [FLOW INDICATOR WH-1296-17-CUZN. sea 20sts810 011917 [SEALING PNG IN 7003 C1733 CUER span BIST TO"i77_ [PRESSURE SPRING [SPRING PRESSURE FOR VALVE] iz pan T1604 [NON Re TURN WAL VE RHVABMTXE 2 U2" VALVE NON RETORIUTE 3 Pen, wars Gogs13e [SuSeING FIXTURE (0OTT3I8] 3 ee AST 521673 [NOVOTHAN GROOVED RING 120-10 130 (9081602) 3a, ZOVes7e ‘805657 [ORT SCRAPER PE 110 122.2112 SA. 15258 0102 | NSERT COVER (BEaseae) Se Bose ATES 102754 [NTA ESPIROMETALIGA DE 29300 PSL 30—[onn 1032265 LUNTA ESPIROME IALICA DE B00 Pal =o [one 19530956 [UNTA ESPIROWETALIGA DE ESTE Pt 30 [uns 1039510 NTA ESROMETALICA DE 4° 1500 PSP 0 ‘902 |RETEN CR39700 BOMBA WRTH (SYNC RGORIVET 2 [Pz ase jens 9955301 QUAD AING SEALS. a 305302 OUTER CAVITY GASKET 7o0—Jon 9057141 SEAL (DETRAS Del PORTA DAFRAGIUA] oN RTT TOTES ‘9052857 JRODAMIENTO 28 Yur W88 C5 Ged eT ar 19000088 [RODAMIENTO 27922 EASM E] C3 educog fear 805407 JRETEN V_ RIN VA Ta0 REDUCTOR for oe ETENV-=FING VA-@8 REDUCTOR) 2 un Was [DIAPHRAGIA BFA 7160-10 FOS. 8 unr, 2a0e207 [ROUND PACKIN RING 140 X 3 FOS. un, possta82 [FLOW INDICATORIDS0 SIZE 1 WiRTHREGULA ur (OVOTHAN GROOVED RING 120 110 X 1300S. 6 3 [UN ses IRT SGRAPER PO - 100 122.24 12 POS.T [UN 202s106 RAG COVER SEAL ACC. 10 DAWG 2106055 POS. 7 [OOEZTGL un 206568 [SEAL 0771-70.740-01 (UTEX) POS. 6 [unr 200160 INSERT COVER Pos. 75. [on 7203867 5011802 [CYL SCREW AviOx20 DM O12, J STAMLESS STEEL POS 77 i — [uw 21000678 1011516 [BUSHING FIXTURE POS. 23 (SAP 20260795). 3 [ont 2304420 2025618 O-RING 54.00 x 300 -03 FRM 552 POS. Jon, ossiase [LINER FOS. 2 3 Jun, 2506021 [CVLNDER SCREW ON OTE TIDUAAOS. STEEL POST aC [TOOTHED Lock WASHER A21-OWN 6797 5:5 POS. @ 3 PERAGH GUIDE ROD POS. 6 3 [unt moarot VALVE HOUSING POS. 3, 2086s [SAFETY VALVE NG 10 POS @ [oN ORDER 44077. [CONNECTION PIECE Pos. 22 UN, TEVLS12 0KO-AIE ING FITTING POS. 35. ‘6 lowe RED 20/12 Z5A3C [STRAIGHT SCREWING ON POS 36 7 [on "GAL20.25R-A3C [SEALING RNa POS. 7 [or DN Te05-AzTHsoCU [SEALING RING DWN 1608 217325-CaFa POS @ lowe [BEARING BUSH (9002135) unr‘208 6012840 [GUIDE RING FOS. « 3 [eA RICO. 5011685 GASKET Pos. s (SAP 70283557] aaa, ‘eso ITIGO, 8012144 RING BRONCE WWWER 3 111 mm POS. 6 (SAP 70256768) 3 fran 205625 RITIGO. 501166 JDELIVERY DIAPHRAGM, COMPIL, POS. 1¥,POS. ‘3 fren [pa meses| ——2aos366 RITICO. 6052153 [DELIVERY DIAPHRAGM, COMPIL: [REP] 328138 JIXTURE FOR GUIDE BUSHING z Sr jens SO11G77 [VALVE CORE [Pen | EOS 2203010 aL TA ROTAGION| Soteto4 VALVE PONTE eo foRATANG Ne 22790@4E ALTA ROTACION S01 630 VaLve Sear [ez | TES Baar LTAROTACION| 30 20s [VALVE Seat RECFERADO, Boze | te as TAROTACOM Stgagir [SHAFT SEALING RING A 2OOXSOKIS DNITOT 1 Pra [eueses | Gamma ie ase Jeemco. 08045 |FORFEDA V-RING ORDER N° 69002-02453 pm GRAM NYAS TSE ORTIOS 1025136 |VALVE COVER SEAL ACS. TO ORWG 2108509 POE. 35 ei ‘ssi [ERITICO. gets [SEAL 07 70074001 (UTEX (9084209) Sea PRADA 1? 20OTSDEE [CRITIC 18136 [GUIDE BUSHING 3 750633 [ERTICD 501+ 7oa [SAL Wik COMS PROFLE BIT, ROTTS OORT ET a2 Jez Zoxsei87 —— ferme ‘S028184 VALVE COVER SEAL ACC TO ORWG 2408878 POS. 7 3 [Pan ‘DRAWING 2406878 [ERITICO 15261 [NUT FOR VALVE aera Za0aaze [GRIT 017604 [ROUND PACKING RING TONg BOOT SORE a2 za DRAWING NF ATE SRTICD Soda 6 [SELF ALIGNING ROLLER BEARING 22700 x COON ESS 2 — [on Teds UATIVPE SEAL a 725maTaS [ou O11 [FLAT SERL [COVER GRAS? APT BEARIN 2 on DENS EAT 2011365 [FLAT SEAL [BEARING HOUSING CRANKSHAFT 2 hou, ea 2401576 ‘014744 [PRESSURE VALVE HOUSING API 3 [ont 2506502 ‘9016160 PRESSURE VALVE HOUSING APL (REPL fon 9022154 [OIAPHRAGH HOUSING (REN ja, 9030083 [DIAPHRAGM HOUSING 3 r2n mse 9052152 [WPHRAGM HOUSING COVER [REF] fom 'SOIE07K [DIAPHRAGM HOUSING COVER (11027021 100RBAT, 3 ean eer 920065 [SUCTION CONNECTION PIECE san 210086 ‘9037157 [SUCTION CONNECTION PIECE [REP [oN ‘9028243 [SUCTION VALVE HOUSING API 3 eax Sa 19092134 | SUCTION VALVE HOUSING APL (REP) 3 fow. 025286 [SUCTION VALVE HOUSING APLE [REP] 3-—[onr 0082 ADAPTER [1021005 ax TET ‘016146 [STOP BALL COCK BX ON=20 (OESFOGUE AGETE AP] “3 fren ‘16a77 028140 [CYL SCREW MiO20 OING12.0.0 STAINLESS STEEL (90TTED2] 2a—feza | — Dae Zee ‘9012862 [PISTON SEAL KIT POS. (SAP STOTTS@E) 6 eza 2407437 5011678 JSOUELE FILTER TYRE 25000Ga0R NOMIC Iz pea GOTI01S [SEAL RO DOS 7, AES seen 671s 5011519 [ROUND PACING RING 109.2 x67 - NOR SO SHOREAFOS. 16 rea. az BUSHING FOR VALVe CLOSURE POS. 22" 3 Iran sees [FLOW INDICATOR Wint200.11.cU2H 3 [ran Zostss10 Soito%7 [SEALNG RNG DW 7603 G17 1-23 CUFA 3 pea, 2o01sTae ‘9011771 PRESSURE SPHING (SPRING PRESSURE FOR VALVE) a : 90056 NON RETURN VALVE REWV2BMTXSS— 12" VALVE NOV RETEN TD, 3 IRA. FT, So s8 aLSHNG FATURE (OO1F995) Se 2A05741 ‘5011371 [ROUNO PACKING RING 168 2<870- BR - SU SHORE APOSTT 3 an, Hateso27 1GOZTO23 [NOVOTHAN GROOVED RING 120-110 130 /0031602 Seen Zier 02657 [ORT SCRAPER PS. T10x 1222572 3 pzn 1525.0, 090107 NS=ET COVER (o038026) 3 pen Basse? [oT 9052254 LUNA ESPROWETHLICA DE 00 FST out [fasszass Junta eS°ROMETALICA De Gye600 FST 70 [Unt [082758 JUNTA ES>ROUETALICA De 63150 PSI 30 [nr 15053510 HUNTA SS°ROMETALIGA DE 4 1600 PST 0 1032002 JRE TEN GA 33700 BOMBA WIRTH [sNCHROORT) 2 pam caso RTS 6053801 JELAD RING SEALS. 350 [ost 1509302 JOUTER caviTy GASKET 0 Jon 500141 [SEAL (CE TRAS G&L PORTA DIFRAGH os, TOT TLTAaN 1093687 JRODAMMENTO 75728 YM WS C3 recto fon 15059655 RCDAMIENTO 27222 EASM Et 23 cc faa 054507 JRETEN RING VA 140 REDUCTOR] or me 9038300 JRETENLV= RING VAG (WECEICTORT 2 fone Tae ‘90s0618 JAPHRAGI BFA 7060-40 POS. 3. —Jow, 2408287 19031604 JROUND PACKIN RING 140 X3 POS.& 3 poste ‘9011006 FLOW NDICATOR2SOD SE 1 WiRTHT REGUL a ‘9031602 JNOVOTHAN GROOVED RING T25 110% 130 POST 3 oo 13031603 DIRT SCRAPER Pc 100 x 12227 12 POS, 7 = 2025810 13094957 DIAPHRAGM COVER SEAL ACC. 10 DRWG 2405055 POS. 7 SORA] = 2108066 9034401 [BERL 0771.70-074000% (UTEX) POS. 9 = 200160 5053025 |INSERT COVER FOS, 12 3 2200887 5011002 CYL SCREW ui1oxz6 DIV OTZG, 7 STAINLESS SYEEL POS Ti 72 [OM 21000878 5041816 [BUSHING FIKTURE POs, 28 (SAP 202607%5) = 3 [owe 242i S0D6E14 [O-RING £4.00 <3.00 09 FRM 692 POS. 5 3 jun 2083126, ‘9031424 JLNER POS, 2 3 Jum 2505021 9034425 CYLINDER SCREW OWN 9121010 S STEEL FOS 3 2 30948 LOCK WASHER AZ\-DIN 6787 8. POS. ¢ [un ‘034427 |DAPHRAGH GUIDE ROD FOS. 6 3 [uN 7o8 ‘3034478 |VALVE HOUSING Pos. 2 [unr 250806 2081402 [SAFETY VALVE NG 10 POS. @ [on ‘ORDER 44200. 2054403 [CONNECTION PIECE POS, 22 on, TEVLSI2.0KO-AIT ‘2034404 [REDUCING FITTING POS. 36. [owe Reb 202 Z8A30 ‘ost405 [STRAIGHT SCREWMIG ON POSSE 7 Jon ‘GAL 20-2ER-9C ‘0sH406 [SEALING RING POS. 97 fom iN 7e08-Az7IS2-CU. ‘0S4407 [SEALING RING OW 1605-017529-C0FR POST 3 [unt 31038 9031206 [BEARING BUSH (032130) jum, 7108606oe net ianedy native be mpineloerab the ditt - zs he ere does . Heviate + ifficulty, ple fer tha matter. to the ‘lanutaciurers technical services leps 6 messy ase weer uid Knock oF Hemmer ADISTIENT. }-—{RReplace Valve Asseniy }—{nensve Propsing Agent [Remove Restictions from Suction Line Replace Piston/Linet Enobeous Gauge Reading Lowtlead }——{inerease Level of Fluid Sepoiy (Charging Punp Capacity Increase Charging Punp Speed ts Retarded Fuld Flow Rewove Restictions {fom Suction Ling EnonebusiGauge Reading “a Sa jar ae Recalibate or Replace Gauge Repair Suction Line “Tighten or Replace Shaft Packing or Seal Al Eaten Sucton Stabilizer — + Hg Ea asset we - : ° poe — Repair and Re-belance Aljow Nate Setting vee Reduce Pump Speed Adjust Suction Stabilizer s ischafge Pressure Repair and Recharge or Replace Same as Low Suction Pressure Sone as Fluid Khock ov Hanmer yFilter Pumped Product Screen Punped Product see Wom Valve Guide - Replace 4, [ Short Valve Lite | freee Same 25 Low Inet Pressure Repair or Replace real Pumped Flaid se Different Materials for Valves/ Seats Filer Punoed Piodict & Flushing Fluid rt Tuicate With Rock Drill Oi a ‘Do lot Ovestighlen Adjustable Packing [creeteaeen rant Plungers Wf Fluid is Clean ‘Check Plunger Aligntent ‘Gheck Packing for Foreign Particles ER [ Replace Sting Box Bushing {Replace Packing Follower [ Replace Lantem Ring Use Recommended Packing}---[Lclean and Polish 0: Renlace Extension Rod Ren 109 Rod Repiace Wipe Rings Check Instatation Directions: Clean and Polish Disphragm Bore Replace Lanlom Ring, FT Check Installation Directions: ‘Oi Balfle Misplaced. Reservoir in Diaphragm Housing Testa Drain Hole At Botiom *~{_clean Drain Hole lean of Replace Air Breather Pressure in Crankcase {Replace Seal Damaged Sealing Lip Replace Seal ‘lean end Polish Bore of Qil Seal Housing { ‘Gleah and Polish Shaft Clean and Polish or Replace Shaft Sleeve Clean or Replace Air BreatheraR ADJUSTMENT.” [[Giesn Tubes and Shot late! Coolant Rate Bearing Adjustnent ‘Check and Adjust Clearances Rotation Loose Plston/Rod Loose Extensis Installation Directions Loose Connecting Rod 4 7 a Ciosahesd Pin ~ ee ed (Pin thing Bearing” Replace Pi in/Eccantic Beaving yi ie 2 Adjust Shoes and Guides or Replace . in Main’os Intermediate Bearing: [Adjust or Replace yo pea co | ,Sheet 2 Drawing No, WIRTH List of Contents of . Sheets 2 2407124e Designation: TPM 8" x 10" Customer: Falconbridge, Ontario / Canada File No,: 86.120.00 - 99 No. Object Drawing No. Pressure valve housing (2305332 15 Suction valve housing 2305331 Valve APIS. 2203044 Delivery diaphragm 2305356 6 Diaphragm stroke control device 2203586 Venting vaive 2404554 7 Pressuse reliefe valve Discharge line for pressur reliefe valve 2001312 Control system scheme 2101982 18 Pneumatic control box 2203628 2/2 way valve (2203323 Vertical float switch 19 Tools list 2406905 Hand pump unit 2305004 20 ‘Hand pump HHP 1000 2406514 Operating instructions for hand pump HHP 1000 2407129 Dismounting device (2302489 Pressure transmitter 2302490 at Plug type nipple 3/8° 2402956 Plug type nipple 3/4" 2302470 Plug type coupling 3/4" 2302484 Connecting nipple 2401874 Plug type nipple 3/8" 2302387 Valve seat pulling device 2101994 Valve seat assembly tool (2203026 22 Pulling device for valve cover 2203593 Wrench for pressure plece 2402787 Scissors for screwed cover 2201208 Cylinder liner pulling device 2305469 23 Torque multipliers Type KS-6RS 24 ‘Storage and maintenance of elastomers WN-0222 Tetamefl —= Ts 12661012. ..| RT mbes = coc te a us BN Liat Some = = Sa eee =: |S ER roe SaRANWIRTH GENERAL INFORMATION ‘The pump may only be used for the purpose Indicated in the order and In the quotation rospectively. Each other application Is considered as being not In accordance with the purpose Provided. The manufacturer does not assume any [lability for damages caused by en Inappropriste application. ‘The guarantees given by WIRTH are stipulated In the Conditions of Supply. Guarantee claims aro only Justified If, In spite of adherence to the operating Instructions, defects to be attributed to WIRTH are caused at the pump. Guarantee claims are to be advised immediately after discovery of the defect to the manufacturing Works, Indicating pump number and order number. I detects are remedied by the customer or a third party without consent of WIRTH, Messrs. WIRTH are not obliged to accept claims. The pump may only be operated with parts supplied by WIRTH. We do not assume any guarantee for products from other suppliers. For repairs it Is recommended to charge Service technicians of WIRTH with this work. Furthermore, we recommend to have the pump inspected regularly by our Service technicians. . 2406204 eWIRTH c SAFETY INSTRUCTIONS ‘Tho pump has been manufactured on the basis of the most recent state of technique and Is ‘operationally reliable. Nevertheless, danger can emanate from tho machine, if the subsequent safety Instructions are not observed. For ait work on the pump, the most recent editions of the regufations for prevention ot ‘accidents have to be respected. The same appiles to supplementary administrative and Internal safety regulations. The pump may be mounted, operated, serviced and repalred by authorized, trained and instructed personnel only. (Electric work may only be executed by the competent qualified personnel. Cc The operating instructions must be read, understood and respected by the competent personnel. This especially applies to safety instructions. IM The operating instructions must be available to the operating personnel at any time. Il The operator is engaged to operate the pump In irreproachable condition only. M_Any operation mode restricting security of the pump must be avoided. Unauthorized modifications and changes of the pump are not allowed. ME The operatar Ia engaged to promptly advise changes restricting security of the pump. I Possible repair work has to be effected immediately after having detected the defects. Ll instructions for the behaviour in caso of extraordinary events (fire, escape routes, etc.) are Cc ‘established by the operating company snd must be known to the operating personnel. Mi Accesses to emergency-off switches and escape routes are always to be kept free. A Your WIRTH pump Is a high-pressure pump. Before offecting any service or repair work stop the pump ! Then shut the fittings at suction and pressure side | Convince yourself that the pump is pressuraless | aN During pump operatton, protection appliances must not bo removed and safety devices ‘must not be put out of operation. The present operating Instructions serve as directives for assembly, operation, servicing and repair ‘of WIRTH pumps. Beyond that, any specific prescriptions and rules also have to be adhered to. 2406205 eWIRTH Technische Daten WIRTH Triplex-Kolbenmembranpumpe TPM 8" x 10" Kolben @ 7 1/2" (190 mm) assembled Piston diameter Kolbenhub 10" (254 mm) Piston stroke Férdermenge 80 m*/hour Flow rate Theor. Férdermenge je Kurbelumdrehung 21,6 Itr. Theor. delivery per crank revolution Hubzahl 66 min* Stroke number Volumetrischer Wirkungsgrad 0,94 Volum. eff. calculated Max. Pumpenférderdruck 465 bar (2393 psig) Max. pump discharge pressure Ubersetzungsverhiitnis des Pumpengetriebes 3,893 Reduction ratio of the pump gear 150 Ibi, sain. Sauganschlu8 ANSI 8" Suction connection Druckanschlu8 ANSI 6" - 1500 Ib/.ain Discharge connection 2407125 rooden2OPERATING MANUAL - WIRTH TRIPLEX PISTON DIAPHRAGM PUMP TPM 8% x 10“ Date: 17.10.1997 2407126e Page | of 25AS 4 OPERATING MANUAL. 4.) TECHNICAL DESCRIPTION. own 4.14 Hydbatlic System For Stud Tensioning 4.5 Gear Lubrication System. 4.1.6 Liner Spray Cooling System. Cy) 41.7 Sump Cone or Procharge Pump (By Others). 42 OPERATING INSTRUCTIONS... 4.2.1 General... a 4.2.2 Lubricating Oil And Cooling Oit Requirements 4.2.3 Gear Lubrication System 0 4.2.4 Liner Spray Cooling System... 43 ROUTINE MAINTENANCE INSTRUCTIONS FOR SLURRY PUMPS 43.1 Genet. 43.2 Lubrication Check Sheer. 43.3 Maintenance Check Sheet 4.3.4 Removal Ard Installation Of | Valve ‘Closures 43.5 Removal And Installation Of Valve Seats. 4.3.6 Removal And Installation Of Pistons & Piston Rods. 4.3.7 Removal And Installation Of Cylinder Liners 4.3.8 Removal And Installation Of Diaphragy 4.3.9 Filling Fluid End With Oil. 43.10 Filling Make Up Tanks With Oil.. 444 REPAIR INSTRUCTIONS FOR SLURRY PUMP 44.1 Removal Of Crankshaft And Connecting Rods. Os 4.4.2 Removal Of Drive Shaft. 44.3 Removal Of Crossheads 4.4.4 Dismounting Of Connecting Rod Big End Bearing. 4.4.5 Mounting Connecting Rod Big End Bearings. 4.4.6 Installation Of Cressheads ... ' 44.7 Installation Of Drive Shaft 44.8 Installation Of Crank Shaft And Connecting Rods. 449 Replacement Of Crasshead, Crasshead Bearing And Stideways Without Removing. Crono 2d 144.10 Removal Ard installation Of Fluid Enc. 25 ane? oO Date: 17.10.1997 2407126e Page 2 of 25O 4 OPERATING MANUAL 4.1 TECHNICAL DESCRIPTION 41.4 Generat The scope of supply comprises 3 slurry pumps type TPM 8" x 10" ‘The prefix TPM comes from the German ‘Triplex Pumpen Membrane” and translates in English to ‘Triplex Diaphragm Pump’. Only the basic pumps are supplied. Main drive motors, suction dampeners, discharge pulsation dampeners, safety valves, control system and PLC are not supplied. When the pumps are brought into service, all of the above items must be provided. 4.1.2 Power End Each slurry pump assembly complete with all auxiliary equipment, is mounted on a heavy duty base frame. All the power end gear components, are encased in a high strength stect frame of welded plate construction, The main shaft complete with pinion, is geared directly to the crankshaft via a herringbone pattern gear. There is a gear reduction from drive shaft to crankshaft of 3.89:1. ‘The drive shaft and pinion is forged and tempered as a single unit, from high strength alloy steel, and machine finished to the final dimensions. The drive shaft is supported at each end dy roller bearings, which allows some axial float for gear wheel self alignment. ‘The crankshaft is cast from high strength alloy steel, and machine finished to the final dimensions. The rigid design of the crankshaft ensures smooth operation and good tooth contact with the drive shaft pinion, The toothed rim is forged and tempered separately, machine finished and bolted to the crankshaft. A recessed machined flange on the tooth rim is tightly bolted to a mating flange on the crankshaft. The torque between crankshaft and tooth rim is transmitled by a combination of bolt tension and friction between the two flanges. ‘The herringbone tooth pattern employed in the gear train between drive shaft and crankshaft, besides providing a very smooth operation, permits heavy gear tooth loading. The crankshaft is supported at each end by self aligning, “taper-lock" roller bearings. One bearing is locked to both the crankshaft and the supporting steel frame, while the other is locked only to the crankshaft. This ensures that the crankshaft has no axial movement, but is still allowed to creep within the temperature expansion limits. ‘The connecting rods are manufactured in one piece, thereby ensuring a highly rigid design. Each connecting rod is driven by the crankshaft through a ‘taper-lock’ roller bearing. The inner case of the roller bearing is taper locked to the crankshaft journal, whilst the outer case is fixed firmly to the connecting rod. In order to achieve the taper lock of the inner case, a split taper sleeve is located between the crankshaft journal and the inner case of the roller bearing, The taper sleeve has a paratle! surface at the inner diameter and a tapered surface at the outer diameter. The roller bearing has the inner case tapered to the same angle as the taper Date: 17.10.1997 2407126e Page 3 of 25© sleeve. The parallel inner surface of the split taper sleeve makes contact with the crankshaft journal. The taper sleeve is in two halves so that it can be placed over the crankshaft journal. Once the taper sleeve is in position, the connecting rod complete with roller bearing is slid over it, so that the taper on the bearing rides over the taper on the taper sleeve, thereby locking the bearing to the taper sleeve, whilst at the same time, locking the taper sleeve to the crankshaft journal. The roller bearing and the taper sleeve are supplied as a machine matched pair by the bearing manufacturer. ‘The other end of the connecting rod drives the crosshead through a parallel 4- roller beating, ‘The parallel roller bearing is an interference fit in the crosshead, The crosshead is made from wear resistant cast steel, hardened and phosphated. Interchangeable bronze alloy slideways, are fixed to the crosshead guide runners which form part of the pump frame. This material combination permits a high contact pressure between the bearing surfaces whilst offering low frictional resistance. The crosshead rod is bolted to the crosshead and moves backwards and forwards with it. The crosshead rod has two primary functions. It drives the piston tod, and forms a seal in conjunction with the gear case stuffing box to keep the lubricating oit contained within the gearbox. The crosshead rod is connected to the piston rod by a link piece and two split ‘couplings. This system allows for removal of the piston without removing the liner. 4.1.3, Fluid End Each pump has three identical fluid ends forged from high strength alloy f a SHORE te steel. The fluid ends are bolted directly onto the pump casing so that there is a direct fluid path from the piston liners to the fluid end. Each fluid end comprises an intermediate piece (one end of which is bolted to the pump housing) which is filled with hydraulic oil, and a diaphragm housing which is bolted onto the conowcn nose free end of each intermediate piece. Each diaphragm housing has a suction valve at the infet end and a discharge valve at the outlet end araoat The principle of operation is that \ ‘SUCTION VALVE MOURNE acne oEreeToRs interwucoure mece there is an enclosed volume of. hydraulic oil contained within the cavity between the piston and the diaphragm. As the pision moves forward, the hydraulic oil pushes the diaphragm further into the diaphragm housing. thus expelling the fluid contained within. For optimum performance, Date: 17.10.1997 2407126e Page 4 of 25oO the amount by which the diaphragm extends into the diaphragm housing is tightly controlled. The axial displacement of the diaphragm is measured by two magnetic detectors. If the diaphragm comes too far back on the return stroke, the magnet will trigger magnetic detector number 2. This will alert the contro! system to charge the enclosed cavity with oil from the make up tank via the make up oil line. A ‘charge’ lamp will illuminate during the charging period. Oil can only be added to the enclosed cavity during the suction (return) stroke when the oil pressure is low. There is a valve mechanism fitted between the oil chamber and the make up tank which ensures that oil can only be added during the suction stroke. The quantity of oil to be added is controlled by the PLC. Each cylinder has its own dedicated make up oil tank, This tank is pressurised by compressed air to 8 barg which exceeds the return stroke cylinder pressure of approximately 2 barg. If the diaphragm is pushed too far forward, the magnet will trigger magnetic detector number 1. This will alert the control system to discharge oil from the enclosed cavity via the make up oil line back to the make up oil tank. A ‘discharge’ lamp will illuminate during the discharging period. Oil ean only be discharged from the enclosed cavity during the pressure . stroke when the cylinder pressure is higher than the pressure in the make up oil tank. There is a valve mechanism fitted between the oil chamber and the make up tank which ensures that oil can only be discharged during the pressure stroke. The quantity of oil to be discharged is controlled by the PLC. Due to the high pressures involved, it is quicker to remove oil from the enclosed cavity than it is to add to it. Bach fluid end is fitted with a conductivity probe which extends into the intermediate piece ‘and makes contact with the hydraulic oil. In the event of a rupture in the diaphragm, slurry will enter the hydraulic oil and the conductivity of the hydraulic oil will change, This will provide a signal to the contro] system to stop the pump and warn the operator of a ruptured diaphragm, Each fluid end diaphragm is powered with hydraulic oil by its own dedicated piston. ‘The slurry pump is single acting, with the fluid being worked by the diaphragm, alternatively drawing info the diaphragm housing on the stetion stroke and expelling it on the discharge stroke. The discharge pressure is determined by the resistance offered by the process against which the pump is operating. The pump will continue to build pressure to meet the system resistance up to the maximum pressure allowed by the safety relief valve, The safety valve is installed on the oil chamber located above the intermediate piece, If the pump is operated safely within the specified pressure limits, the safety release pressure should never be reached. Each diaphragm housing incorporates a discharge valve and a suction valve. The discharge valve is bolted directly to the discharge port of the diaphragm housing. The suction valve is bolted to a 90 degree connection pipe, the other end of which is bolted to the suction port of the diaphragm housing. The connection pipe has a support welded to it which is bolted to the pump skid. In the assembled condition, there is a direct fluid path from the suction valve through the diaphragm housing to the discharge valve. Spring loaded valves in the suction and discharge valve housings automatically determine the required flow path. During the suction stroke, the suction valve is open and the discharge valve is closed. This allows the pump to draw fluid from the low pressure suction line. During Date: 17.10.1997 2407126e Page 5 of 25the discharge stroke, the discharge valve is open and the suction valve is closed. This allows the pump to expel fluid to the discharge line. The suction and discharge valves open and close automatically due to the fluid pressure either assisting or opposing the valve spring. ‘The suction and discharge valve housings have carefully worked transitions to give good fluid flow conditions and to reduce the material strains at critical points. The valve chambers have. been designed to comply with the requirements for valve installation according to Size-API 8. ‘The inlet and outlet valve covers on the suction and discharge valve housings, and all of the component parts therein are identical and interchangeable. The valve covers incorporate a hydraulically operated bolt tensioning system which permits rapid and safe completion and removal of the flange connections. The three discharge valve housings are manifolded together by one common pipe with a discharge flange at cach end. ‘The pumps are supplied with a suction manifold. Each suction valve housing is connected to the suction manifold. The manifold has three fluid inlet connections, one at each end as well asa central inlet connection, This provides flexibility for the suction pipework as the operator need only supply a single line from the precharge pump to any one of the manifold pipe inlet connections. The two inlet connections that are not used should be blanked off. 4.1.4 Hydraulic System For Stud Tensioning. The WIRTH patented stud tensioning system is used to tighten the studs on critical high pressure connections... The detailed design differs according to the application. However, the principle of operation is to assemble the connection with the studs lightly torqued, then to use the hydraulic tensioner to stretch the studs by a predetermined amount. Whilst the studs are in the stretched condition the nuts are nipped tight. Upon relesse of the pressure which is holding the studs in the stretched condition, the elastic properties of the studs will attempt to restore them to their original length. Since the studs are locked to the stretched length by the nuts, a residual tension is left in the studs. This residual tension pulls the two connecting surfaces together. “The pressure used to tension the stud is applied by a hydraulic hand pump. “The hydraulic tensioning system is used for securing the valve closures. “The hydraulic tensioning system provides @ high level of safety and ensures that the forces pulling the connecting surfaces together are evenly distributed. 4.1.5 Gear Lubrication System. ‘All of the roller bearings and the crosshead guides are lubricated by a pressurised, lubrication system, Oil is circulated to all of the bearing surfaces by means of an electrically driven circulating pump. Two positive displacement gear type circulating pumps are provided. However, the pumps should be arranged so that one pump is operational and the other pump is on standby, Each time the slurry pump is assigned, the duty and standby lubricating pumps should change roles so that both pumps are worked an equal amount. Each of the circulating pumps has a non-return valve fitted to the discharge pipe so that one pump can not back feed the other. The base of the gear box acts as a sump for oil storage. The main ring gear is partly submerged in the sump oil and provides additional splash lubrication, as it throws the oil around the gear box. The pressurised lubrication system incorporates an oil filter. A pressure Date: 17.10.1997 2407126e Page 6 of 25co ‘gauge is installed in front of and behind the oil filter. Adjustable flow indicators are installed in the feed line to each lubrication point. The flow indicators have a ball which floats when oil passes so that it gives a clear indication that the bearings are receiving sufficient oil. ‘The common discharge line from the oil pumps is fitted with a pressure relief valve which limits the discharge pressure to 12 bar. A pressure switch is included in the system to indicate loss of lubricating oil pressure. Immediate action must be taken to stop the slurry pump on loss of oil pressure. ‘The gear lubrication system should be running and showing pressure before the main slurry pump drive motors are energised, ‘The lubrication system employed with the WIRTH slurry pumps has been proved to be very effective and reliable over many years and renders the pumps almost maintenance free. 4.1.6 Liner Spray Cooling System. ‘The cylinder liners are cooled by a dedicated cooling oil system. Oil is circulated from a storage tank by a positive displacement gear type circulating pump through the hollow piston rod into the cavity behind the piston and then back to the tank. The storage tank is integrated imo the main frame. Upon discharge from the pump, a pipe takes the cooling oil to a distribution manifold. The distribution manifold has three outlet connections to feed each cylinder liner. Flexible hoses take the oil from the manifold outlet connections to an inlet connection point on each of the link pieces that connect the piston rod to the crosshead rod. This end of the hose travels back and forth with the piston rod. The link piece and the piston tod have a concentric hole running along their complete length. Oil is continuously pumped along the piston rod where it is sprayed out radially into the cylinder liner just behind the piston, The cylinder liner is open ended so that on the return stroke of the piston, the oil is swept back into the casing from where it drains back to the oil storage tank directly below. The volume of oil circulating is sufficient to dissipate the heat without the need for a heat exchanger, ‘The cooling oil storage tank is supplied with a drain comnection for cleaning if required. A flow switch is included in the system to indicate loss of flow. Immediate action must be taken to stop the slurry pump on loss of flow. The liner spray cooling system should be running and showing pressure before the main slurry pump drive motors are energised. ‘The oil used to cool the eylinders has the same specification as the oil used to power the diaphragen, 4.1.7 Sump Cone or Precharge Pump (By Others). : A precharge pump or a sump cone must be used to deliver fluid to the slurry pump suction at a flow and pressure sufficient to satisfy all operating conditions. The minimum precharge pressure required to satisfy the above criteria is 1.5 barg, but the recommended precharge pressure for normal operations is 3 barg. ‘The sump cone / precharge pump is not part of WIRTH's scope of supply. ‘The use of a sump cone or precharge pump has the following benefits, * Increase in effective pressure to ensure smoother operation of the pump. This is more critical at high pumping rates. Date: 17.10.1997 2407126e Page 7 of 25oy cc * Increase in the volumetric efficiency. ‘+ Increased lifespan of pump consumable parts. 4.2 OPERATING INSTRUCTIONS 4.2.1 General ‘The slurry pumps have been function tested by WIRTH prior to delivery. During installation, great care should be taken to ensure that no debris is allowed to enter the pump or auxiliaries through any of the open pipe connection ports. If any of the inspection covers are removed for any reason, they should be replaced immediately afier the task in hand has been completed. ‘The suction and discharge pipework should be flushed clean prior to the initial pumping operation taking place, and a temporary commissioning strainer showld be included in the suction pipework, Attention ! Before comissioning all stud connections has to be checked acc. to instruction manual. 4.2.2 Lubricating Oil And Cooling Oil Requirements Prior to leaving, the factory, the oil has been drained from the gear case and from the cooling oil tank. Prior to first start up, the oil reservoirs should be filled with oil as follows. 1, Gear ease oil Check the gearing for cleanliness prior to filling with oil. Volume of oi required for each pump = 530 litres. The oil level can be checked by a sight glass at the rear of the gear frame, or by a dipstick. Both are provided. Oil specification; For temperature range: -1°C to +68°C DIN 51517 part 3 ISO-VG 320 For temperature range: -20°C 052°C «DIN. SISI7 part 3 ISO-VG 220 Note: Oil must be filtered (o a minimum of NAS 8 prior to use. 2. Fluid end assembly. (oi! chambers) Volume of each outer fluid end = 30 litres Volume of centre fluid end = 25 litres. (intermediate piece is shorter on centre assembly) Oil specification; hydraulic oil IS0-VG-46 3. Make up oil tanks. Volume of centre tank = 15 litres, Volume per pump = 45 litres. (3 tanks per pump) Oil specification; hydraulic oi! ISO-VG-46 4, Cylinder liner cooling oil. Check oil storage tank for cleanliness. Total volume of cooling oil = 185 litres Oil specification; hydraulic oil ISO-VG-46 Date: 17.10.1997 2407126e Page 8 of 25,4.2.3. Gear Lubrication System. ‘The starting logic for the main slurry pump drive motors must ensure that the gear lubrication system is running and pressurised prior to energising the main drive motors. ‘When the oil is at running temperature, the discharge pressure from the oil pump should not exceed 10 bar. During the warm up period, the pressure may rise slightly above this. In any event, the pump relief valve is set at 12 bar which is the maximum allowable system pressure. If the pressure drop across the filter is greater than 2 bar, then the filter must be cleaned. Pressure gauges are located immediately upstream ( in front) and downstream (behind) of the filter. If the upstream pressure gauge reads in excess of 2 bar above the downstream gauge, then the filter is blocked and requires cleaning or renewal. The minimum required pressure downstream of the oil filter is 2 bar. This is the minimum pressure that is required to ensure that all of the bearings are adequately supplied with oil. If the pump discharge pressure exceeds 10 bar during normal operation, then the system pressure balance must be checked. First check that the throttle screws on all of the flow indicators are correctly adjusted. The flow indicators are provided with a throttle screw that regulates the flow to each lubrication point. When properly adjusted, the indicator ball in the sight window should float freely without bottoming. The adjustment of one flow indicator has fan effect on the others, so that the overall system balance is achieved by a trial and error procedure. If the ball bottoms, there is no flow and the bearings will be destroyed. If the pump discharge pressure remains high after the flow has been balanced, then the rest of the system (pump, oil filter, and pipelines), must be checked for blockages. ‘Two electrically driven "gear type" oil pumps are provided, with their outlets manifolded to one common discharge line. One pump is nominated the duty pump and the other pump is on standby. Each time the slurry pumps are assigned, the duty and standby pumps should ebange roles. A flow switch is included in the line between the filter and the first flow indicator, On loss of flow, the standby pump shall automatically start up and take over the duty role. If the flow is not reinstated, the slurry pump must be shut down and the cause of the lubrication failure investigated. ‘The oit flow path around the lubrication points is described as follows; * Oil passes through the flow comtroliers to the upper and lower crosshead slideways, through the slideways and into longitudinal groves in the crosshead thereby iubricating the sliding contact surfaces. The oit then passes through the crosshead assembly, to the crosshead roller bearing. The oil is then transferred from the crosshead bearing, by a tube fastened to the outside of the connecting rod, to the bearing that connects the connecting rod big end to the crankshafi journal. Each main drive shaft bearing is supplied with oil via a separate flow controller. Each crankshaft end bearing is supplied with oil via a separate flow controller. Alll three stuffing box seals are supplied with oil via a single common flow controller. The main gear drive is supplied with oil at the point of tooth engagement via a separate flow controller. Date: 17.10.1997 2407126e Page 9 of 25Additional to the pressurised oil feed system, the main ring gear is partly submerged in oil, and picks up and throws oil around the gear box as it rotates, thereby incorporating an cil splash system, ‘The first oil change should be after 600 operating hours, Subsoquent oil changes should be at 3000 operating hour intervals, or six months, whichever comes first. Note; During start up in extreme cold weather, when the slurry pump has been lying idle for some time, the lube oil pump must be run in advance of starting the slurry pump for a period of fime sufficient to allow the lube oil to establish a free flow to the bearings. Flow to the bearings is confirmed by the flow indicators throughout the system. The auxiliary drives must not be started at temperatures below +5°, 4.2.4 Liner Spray Cooling System. ‘The starting logic for the main slury pump drive motors must ensure that the liner spray cooling system is running and pressurised prior to energising the main drive motors. The discharge pressure from the cooling oil pump is up to 2 bar. A flow switch is included in the system between the pump and the discharge manifold. On loss of flow, the slurry pump should be shut down and the fault investigated, An electrically driven gear pump is used to circulate the cooling medium (hydraulic oil). Date: 17.10.1997 2407126e Page 10 of 25Os 4.3 ROUTINE MAINTENANCE INSTRUCTIONS FOR SLURRY PUMPS. - Reference dwg. 2001409, section 5 4.3.4 General This section covers the replacement of items that may require renewal as part of a regular maintenance programme or jtems that need replacing as part of the operational requirements. Before any maintenance work is carried out, the following safety measures must be observed: + The operators permit to work system must be adhered to. ‘The slurry pump must be stopped and isolated from the electricity supply. The fluid end must be depressurised. ‘The work area must be adequately lit so that good all round vision is assured. Safe access must be provided to all items of equipment that cannot be reached from floor level. * The lubricating oil and the exterior surfaces of the slurry pump can reach temperatures approaching 60°C during operation. Maintenance personnel must be aware of this, and a sufficient cooling off period should be allowed prior to maintenance on hot parts of the pump. + The gauge on the hydraulic hand pump must be periodically calibrated to ensure accurate pressure readings are assured, Date: 17.10.1997 2407126e Page 11 of 25,cr 4.3.2: Lubrication Gheck Sheet EQUIPMENT: 3 off WIRTH SLURRY PUMPS. ACI OPP T Hours | oawy | weeey | MONTH MONTH YEARLY Check gear case oil level x Check press drop across filter x Change gear case oil & check filter + Check / fil oil pot on finer spray pump x All instructions regarding lubrication and maintenance are included in referenced drawing 2001409, section 5 > 4.3.3 Maintenance Check Sheet Check suction dampener precharge Check discharge pulsation dampener precharge ‘Check holding down bolts and fluid end clamping bolts Inspect main gear drive (coincident with | 4000 il change) Calibrate hydraulic hand pump press gauge NOTE 1: C.A refers to certifying authority or operator approved inspection agency. 1st oil change after about 600 operating hours, further oil changes every 3000 operating hours, after 6 mounths at the latest. Date: 17.10.1997 2407126e Page 12 of 25O 4.3.4 Removal And Installation Of Vaive Closures Removal, 1. Depressutise the fluid end. 2. Connect the hydraulic hose from the hand pump to the snap-on connector on the valve closure. 3. Apply a pressure of 970 bar to the hydraulic piston. This will stretch the flange retaining studs by a minute amount and move the upper assembly away from the valve body. . Unscrew the jacking plug with the socket wrench provided. . Depressurise the hydraulic piston. Disconnect the hydraulic hose from the snap-on connector. 7. Unserew the valve closure ring with a torque bar, - Remove insert cover with the special pulling tool provided. . Remove sealing ring. RNase Installation Inspect the sealing ring and renew if damaged. . Clean the sealing surfaces on the insert cover, valve body, and sealing ring. . Install the insert cover complete with sealing ring. Screw in the valve closure ring and tighten with torque bar. Connect the hydraulic hose from the hand pump to the snap-on connector on the valve closure. 6. Apply a pressure of 950 bar to the hydraulic piston. This will stretch the flange retaining studs by a minute amount and move the upper assembly away from the valve body. 7. Serew in the jacking plug and tighten it with the socket wrench provided,. until it nips against the piston. 8. Depressurise the hydraulic piston. The residual tension induced into the flange retaining studs by stretching them, will pull the complete upper and lower assemblies together, thereby concentrating all of the closing force on the sealing ring 9. Disconnect the hydraulic hose from the snap-on connector yeeNe CAUTION: To avoid damaging the threads and sealing surfaces, the valve closures must be retightened, using the above procedure, after two hours running time, Periodic checks must also be made and the closures should be tightened as required. ate. 17.10.1997 2407126 age 13 0°25ov 4.3.5 Removal And Installation Of Valve Seats. - Reference dwg. 2001306, section 14 The valve seats are removed by using the hydraulic expelling device supplied in the special tools package. Removal, 1. Remove the valve closure, insert cover and sealing ring as described in section 3.3.4 2. Remove the complete valve assembly comprising, valve cone, valve pressure spring, valve nut and valve plate. The complete valve assembly lifts clear by hand. 3. Replace the valve closure and insert cover and tighten with the torque bar, It is not necessary to tighten with the hydraulic tensioner. Note; Replacement of the valve closure is a safety precaution to prevent the valve seat from flying out when it is expelled by hydraulic pressure. This safety measure must be adhered to. 4. Connect connector (4) of the hydraulic expelling device (drawing 23 02489), to the snap- on pressure terminal (19) (drawing 2001306, section 14). 5. Connect the hand pump to expelling device snap-on connector (2) and pressurise to 150 bar. 6. Move the hand pump to expelling device snap-on connector (3). Using connection (3) intensifies the hydraulic pressure delivered by the pump three fold, giving a maximum output pressure from the hydraulic expelling device of 4500 bat. 7, Increase the pressure until the valve seat is expelled. installation, Prior to installing the valve seat, thoroughly clean the tapered surface of the seat and the mating taper in the valve body. 1. Insert two new O-rings into the grooves in the valve seat. 2. Ensure that the mating tapered surfaces are clean and dry. Note: Do not use oil or grease on the tapers or on the O-rings. 3. Insert the valve seats into the valve body and tap them home-using a special tool (see dwg. 2203026) and a hammer. Dut: 17.101997 24071266 Page {dof 25ce 4.3.6 Removal And Installation Of Pistons & Piston Rods - Reference dwg, 2001317, section 7 Removal 1 Remove the two split couplings, that clamp the piston rod and crosshead rod together. ‘Mark the couplings so that they are replaced back in their original positions, Do not interchange couplings between cylinder compartments. Move the crosshead rod slightly to the rear so that the link piece may be removed. 3. Remove the link piece and end cover plate, It is not necessary to disconnect the cooling oil supply hose from the link piece. 4 Move the crosshead rod forward until it touches the piston rod and use one of the split couplings to lock them together. 5 Move the crosshead rod as far back as it will go. This will pull the piston rod with it until the piston is drawn clear of the cylinder. 6 Disconnect the split coupling and remove the piston rod. Installation 1. Install sealing rings (14) and (21) at either end of the piston rod. 2. Assemble piston to piston rod and tighten end nut (20) to a torque of 1400 Nm, 3. Grease the piston. 4, Introduce the piston and piston rod into the cylinder, paying careful attention that there is no damage to either component, 5. Move the crosshead rod forward until it buts end to end with the piston rod and push the piston rod into the cylinder far enough to allow the link piece to be assembled. 6. Move the crosshead rod back a suificient distance and insert the link piece. Oil the clamping bolts on the two split couplings and torque up to 700 Nm. re 4.3.7 Removal And Installation Of Cylinder Liners Removal . Remove the piston rods and pistons as described previously in section 4.3.6 . Unscrew and remove the nuts that secure the liner clamping flange. . Pull the finer clamping flange clear of the cylinder liner. . Remove the stud bolts that secure the liner clamping flange. . Use special lifting tool (drawing 2305469, section 22) to hoist the liner clear of the pump. Installation, 1. Clean the cylinder liner, fit a new end seal and grease it, Clean and grease the bored surface in the pump frame that mates with the outer diameter of the cylinder liner. 2. Install the cylinder liner using the special lifting tool. (drawing 2305469, section 22) 3. Replace the stud bolts, clamping flange and nuts. Tighten nuts to a torque of 1100 Nm. 4, Install the piston rods as described in section 4.3.6 peepee Date, 17.10.1997 24071266 Page 15 0f 254.3.8. Removal And installation Of Diaphragm. - Reference dwg, 2001306, section 14 Removal 1. Isolate the slurry pump from the suction and discharge pipework so that no fluid ean enter the pump during removal of the diaphragm. 2. Ensure that there is no pressure in the H.P slurry pipework. 3. Vent the diaphragm housing by opening the venting valve located at the front of the suction valve housing. 4. Drain the cylinder housing of hydraulic oil by opening the drain valve located near the flange of the fluid end intermediate piece. 5. Serew into position, the two guide bars that are used to support the diaphragm housing, cover while it is being withdrawn, 6, Bolt the temporary lifting lug onto the top surface of the diaphragm housing cover flange and sling it to a crane. (the cover weighs 750 ke) 7, Remove all of the housing cover nuts using the special torque wrench. 8. Use the three jacking bolts to jack the housing cover away from the housing body. 9, Slide the cover along the guide bars and remove it by crane. 10.Pall out the diaphragm complete with guide rod and magnet. 11 Disconnect the guide rod and magnet ftom the diaphragm. Installation I. Assemble the diaphragm complete with guide rod and magnet ready for installation. 2. Ensure that the diaphragm housing and cover are clean and the ring groove in the housing is clean, . Insert the diaphragm into the housing and push home. Fit a new seal into the ring groove in the housing. . lift the cover onto the guide bars. . Lightly grease the mating surfaces of the cover and housing. . Push the cover home, being careful not to damage the seal. . Replace the cover nuts and torque to 6000 Nm. Prawn aw 4.3.9 Filling Fluid End With Oil The fluid end assemblies must only be filled one at a time, When filling the fluid end, ‘extreme care must be taken to ensure that the oil cavity is not overfilled. If the oil cavity is overfilled, the volume control system will not be able fo discharge the excess oil in the first stroke and damage to the diaphragm may result 1 Move the piston to the rear dead centre position as follows; + Remove the access plate from the end of the drive shaft cover. © There is a hexagon, 75 mm across the flats located at the end of the shaft. Use a socket spanner to tum the shaft until itis at the rear dead centre position, 2 Open the vent valve at the rear of the diaphragm housing. 3 Pressurise the slurry side of the diaphragm housing to approximately 2 bar. ‘This will ensure thet the diaphragm is pressed hard against the housing wall. With the diaphragm in Date: 17.10.1997 2407126e Page 16 of 25this position, the magnetic switch will inform the control system that oil needs to be added and the ‘charge lamp wil illuminate, 4 Atthe control panel, select ‘manual’ on the filling selector switch. 5 Select the required chamber (1, 2, or 3) on the chamber select switch. 6 Push the diaphragm charge button and filling will start. The charge buiton is spring return, so that it must be kept in the pressed in position otherwise filling will stop. 7 Fill the chamber until all of the air has been expelled from the bleed line, and only oil emerges. 8 Shut the bleed valve. 9 Stop filling when the ‘charge’ lamp goes out, 10Note the oil level in the make up oi! tank and add one litre more to the chamber. 11 Bleed air fiom the safety valve with the hose provided. Repeat the above process for the other two chambers. 4.3.10 Filling Make Up Tanks With Oil ‘The procedure is the same for each of the three tanks. This is written for tank number 1 1. On the control panel, select chamber number I. This will vent the air pressute from tank number 1. 2. Use a hose with snap-on couplings to connect the oil feed pump to make up tank no 1. 3. Open the filling valve for make up tank number 1. 4, Pump oil into the tank until the tank level indicator shows full (15 litres). 5. On the control panel select ‘tank’, This will pressurise the tank to 8 bar ready for service. 4.4 _ REPAIR INSTRUCTIONS FOR SLURRY PUMP. This section covers repairs or overhaul to the equipment due to breakdown outside the normal maintenance scope. Before any repairs are undertaken, the slurry pump must be isolated from the electrical supply and the fluid ends must be depressurised, 44.1 Removal Of Crankshaft And Connecting Rods - Reference dwg. 2001317, section 7 & dwg. 2201876, section 9 1 Remove the gear casing cover, 2 Remove the piston rods as described under section 4.3.6 3. Remove the two inspection covers, one each side of the pump, that give access to the crosshead assemblies. 4 Remove the right hand side crosshead centre pin, and the left hand side crosshead centre pin, Access to the middle crosshead is not possible at this stage. The crosshead centre pins are removed as follows: ‘+ Remove the four outer bolts from the crosshead centre pin retaining plate. Do not touch the three inner bolts, as these are bolted to the centre pin, Date 17.10.1997 2407126 Page 17 0f 25* A tapped hole is located adjacent to each of the four outer bolt positions. These four tapped holes arc jacking points for drawing the centre pin out of the crosshead assembly. + Take the four bolts previously removed, and screw them into the jacking points until they bottom against the crosshead frame. * Continue to tighten the bolts. This will jack the centre pin out of the roller bearing. When the jacking bolts have been tightened to their full length, remove the three bolts that hold the jacking plate to the pin, and remove the jacking plate. The centre pin should be free enough to pull clear. There is a concentric hole running part way through the pin which is used for lubricating the pin bearing. This hole has a M24 thread at the beginning, and a pulling bar can be screwed into this thread to help pull the pin clear of the crosshead. If it does not easily pull clear, a bit of persuasion may be necessary, otherwise, use longer jacking bolts. 5 Unbolt the right hand side (looking from power end towards fluid end) crosshead staffing box from the bulkhead and push it forward towards the cylinder liner. 6 Push the right hand side crosshead forward into the space made available by removing the stuffing box. (The crosshead is no longer connected to the connecting rod as the centre pins have been removed.) This will leave a clear path to give access to the middle crosshead through the right hand side inspection hateh, the cover of which was removed in step 3. When moving the crosshead forward, be careful that the free end of the connecting rod does not drop and darnage the crosshead slideways. 7 Line the connecting rod little end with wood so that it will not damage the crosshead slideway when the crankshaft is tuned, 8 Turn the crankshaft so that the middle crosshead is accessible fiom the right hand side inspection hatch. 9. Remove the centre pin from the middle crosshead, Follow the procedure described in step 4 above with the following exception: + When the centre pin has been jacked free, remove the three bolts that hold the jacking plate to the pin, and remove the jacking plate. This is done because there is not enough” space to pull the pin clear with the plate still attached to it, * Tap the pin clear from the left band side using a piece of hard wood. There is a concentric hole running part way through the pin which is used for lubricating the pin bearing. This hole has a M24 thread at the beginning, and a pulling bar can be screwed into this thread to help pull the pin clear of the crosshead. 10 Remove the crankshaft bearing cover plate (dwg, 2201876 item 19) from both sides of the pump. 11 Slacken off the four bolts in the end plate (11) by about 10 mm. (The end plate locks the tapered sleeve to the crankshaft). Do this at both sides of the pump, 12 In order to break the taper lock between the bearing and the crankshaft journal a special hydraulic release tool (not supplied) is required, Screw the hydraulic release tool on to the threaded end of the tapered sleeve (10). Connect the hydraulic pump to the release too! and pressurise until the taper lock is broken, Do this for both bearings. Date: 17.10.1997 2407126e Page 18 28‘The end plate (11), which has been slackened off, (in step 11), will stop the tapered sleeve from springing out too far. 13 Remove the fink piece from both sides of the pump frame (dwg. 2304718, section 8). When the link piece is removed, there will be a gap in each side of the pump frame, through which the crankshaft can be withdrawn. Remove each link piece as follows: ‘* Use the special hydraulic stud tensioner SSV M48 to undo the nut on the M 48 clamping stud. A hydraulic pressure of 1050 bar is required to release the nut. ‘+ Remove the M 48 clamping stud, + Remove the link piece. Two tapped holes M 20, are provided in each link piece so that eye bolts can be used to lift the link piece clear of the pump. 14 Attach a soft sling to the crankshaft and take the weight in preparation of removing the bearings. The total assembled weight of the crankshaft, including the connecting rods, but not including the end bearings is 8 tonne. 15 Push all crossheads forward to the end stop so that the connecting rod little ends are clear for removal. Line the connecting rod little ends with wood so that they will not damage the crosshead slideways. 16Remove the end plate (dwg, 2201876 item 11) and tapered sleeve (10) from each end of the crankshaft. 17 Remove both end bearings (09), complete with bearing housings (14). ‘The procedure for each side is as follows: + Remove all twelve M 24 bolts (17) from the bearing housing, * Screw a round steel bar, (25 mm diameter and 600 mm long with a M 24 thread at one end, thread fength 50 mm approximately) into two of the holes vacated by the M 30 bolts. Use the holes located at 3 O-clock and 9 O-clack. These two bars will support the weight of the end bearing and bearing housing when they are being removed. + The bearing housing (14) is provided with two, diametrically opposite, M 24 tapped holes to be used as jacking points for withdrawing the housing. + Use two M 24 bolts 300 mm long to jack out the housing. Initially, do not jack the housing all of the way out of the gear frame. Leave approximately 30 min of the housing in the frame. ‘+ Chock the crankshaft journal with wooden blocks and allow the blocks to take part of the weight, * Pull the housing, complete with roller bearing clear of the gear frame, and remove it Note: The feft hand and right hand bearing housings are not interchangeable. The right hand bearing housing has a retaining lip which prevents lateral movement of the bearing. The left hand bearing housing docs not have a retaining lip which allows the bearing to move laterally to compensate for expansion due to temperature changes. 18 Remove the crankshaft assembly complete with connecting rods, by overhead crane. Date: 17.10.1997 2407126e Page 19 of 25yeuau 4.4.2 Removal Of Drive Shaft = Reference dwg. 2203190, section 9 Removal of the drive shaft is only possible if the crankshaft has been removed first, 1 Remove the coupling from the drive shaft. 2. Remove both bearing cover plates (09 and 13) by unbolting the eight M 20 bolts, 3 Each end of the shaft is drilled and tapped M 48 and fitted with a M 48 bolt. Unscrew the M48 bolt at each end of the shaft and attach one end of a sling to each bolt. Hang a crane hook in the centre of the sling and take the weight of the shaft. 4 Push the shaft sideways. If the force is from right to left, the left hand bearing will be pushed out in its entirety with the shaft, and the inner ring of the right hand bearing will be pushed out with the shaft. The outer ring and the roller cage of the right hand bearing will remain in the gear frame. The complete shaft can be removed through the bearing housing once the bearing has been removed. The shaft can be pushed out from tight to left, or from left to right, whichever is the easiest. 4.4.3 Removal Of Crossheads Note: This section assumes that the crankshaft has already been removed. To remove the crossheads without removing the crankshaft, see section 4.4.9. ‘The crossheads are removed through the back of the gear case. The crosshead and crosshead rod are removed as an assembled pair. The crossheads are removed with the aid of a piece of rectangular section hard wood, 100 mm x 80 mm x 5000 mm long. The hardwood shaft is wedged into the rear cavity of the crosshead with a wooden block. A sling is placed around the hardwood shaft immediately behind the crosshead. The weight of the crosshead is taken by the sling, and the whole assembly is balanced by someone exerting a downward force on the end of the hardwood shaft. 4.4.4 Dismounting Of Connecting Rod Big End Bearing ~ Reference dwg. 2201876, section 9 The crankshaft assembly must be removed from the pump before the connecting rods can be disassembled, 1. Remove the outer bearing cover plates (19). 2. With the cover plates removed, the bearing lock nut is accessible. There is a pinch bolt on the bearing lock nut which, when tightened, pinches the threads on the look nut against the threads on the tapered sleeve and prevents the lock nut from unscrewing during, operation. Unscrew the pinch bolt, . Unscrew the bearing lock nut one full tum using a "C" spanner. . Connect the hydraulic pump to the hydraulic injection ports on both halves of the tapered sleeve. Apply hydraulic pressure to break the taper lock. . Remove the hydraulic pump connectio: . Take the weight of the connecting rod with a sling, . Unscrew and remove the bearing lock nut. . Remove both halves of the tapered sleeve. Remove the connecting rod by guiding it over the crank offsets, aye Date: 17.10.1997 2407126e Page 200F25