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Doc No: OMM50002312

Rev: C Page 1 of 54

Subject to contractual terms and conditions to the contrary, this document and all the information contained herein are the confidential and exclusive

property of FMC Technologies, and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by FMCTI.

OPERATION AND MAINTENANCE MANUAL, W11 TRIPLEX PUMPS

Rev

ECN No.

Date

Reviewed By

Approved By

Status

C

5041126

30-SEP-2016

Rothe, Michael

Kowalski, Christopher

RELEASED

Summary:

This is a manual for FMC W11 triplex piston pumps. These pumps include a pinion drive
for internal gear reduction; they have a stroke length of 2.75 inches, and maximum
continuous duty power ratings ranging from 20 horsepower (15 kilowatts) for the W1118
to 30 horsepower (22 kilowatts) for the W1122. The maximum intermittent duty rating is
24 horsepower (18 kilowatts) for the W1118 to 36 horsepower (27 kilowatts) for the
W1122. Refer to part number

for printing information.

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2
3
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Summary of Contents for W11

Page 1: ...CN No Date Reviewed By Approved By Status C 5041126 30 SEP 2016 Rothe Michael Kowalski Christopher RELEASED Summary This is a manual for FMC W11 triplex piston pumps These pumps include a pinion drive for internal gear reduction they have a stroke length of 2 75 inches and maximum continuous duty power ratings ranging from 20 horsepower 15 kilowatts for the W1118 to 30 horsepower 22 kilowatts for ...

Page 2: ...Power Source 11 4 3 Suction Piping Recommendations 12 4 4 Discharge Piping Recommendations 13 4 5 Multiple Pump Systems 14 5 0 How to Start a Pump 15 6 0 Lubrication of the Power End 17 6 1 Recommended Lubricants 17 6 2 Oil Changes 17 7 0 Inspection and Preventative Maintenance Chart 19 8 0 Estimated Life of Wearing Components 20 9 0 Component Parts List 21 10 0 Service Procedures 25 10 1 Replacin...

Page 3: ... and all the information contained herein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI 16 0 Glossary of Commonly Used Terms 49 17 0 Reference Information 52 18 0 MAINTENANCE LOG 53 ...

Page 4: ...gies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI List of Figures Figure 1 W11 Pump Assembly Features 7 Figure 2 Power End Components 21 Figure 3 Fluid End Components 23 Figure 4 Using the Installation and Knock Out Tool 31 Figure 5 Typical W11 Disc Valve Assembly 32 Figure 6 Illustration of the P534694 or P534695 Ball Valve Knock...

Page 5: ... disclosed or made public in any manner prior to express written authorization by FMCTI List of Tables Table 1 Allowable Working Pressure for Steel Pipe psi 100 F 13 Table 3 W11 Maintenance Schedule 19 Table 4 Power End Component List 22 Table 5 Fluid End Component List 24 Table 6 Torque Values for Critical Pump Fasteners 42 Table 7 Torque Values for Xylan Coated Fasteners 42 Table 8 Clearance Cha...

Page 6: ... a pressure relief valve rupture disc or other type of properly sized over pressure safety device installed Always use a pressure gage when operating the pump The pressure must never exceed the maximum pressure rating of the pump or damage may occur This damage can cause leakage or structural damage resulting in injury to personnel Ensure that no valves are placed between the pump and pressure rel...

Page 7: ... to sump Many piston and liner combinations are offered to provide maximum service life for each application Magnetic drain plugs remove tramp iron from the oil bath Integrally cast and machined feet to provide rigid and precise mounting Disc type valves feature tough durable materials and generous flow areas to extend service life Ball valves are available for fluids with solids that will foul co...

Page 8: ...or storage As a general rule for pumps in corrosive fluid applications the fluid end should be drained flushed with water or another non corrosive cleanser and compressed air should be used to blow dry whenever idle 3 2 Short Term Storage for Severe Environments If the pump has been in service drain any fluid from pump fluid end flush the fluid end with water to clean out any of the remaining pump...

Page 9: ... preservative and lubricating oil mixture from the power end crankcase Remove the rear cover and apply recommended crankcase lubricant Refer to Table 2 in Section 6 0 to the pinion bearings Reinstall the rear cover drain plug breather filler cap piston cup seals and any other components that were removed for storage Once these steps have been completed follow the normal pump start up procedures ou...

Page 10: ...formation contained herein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI this purpose Remember that any fluid that poses an environmental hazard or is toxic must be handled and disposed of properly ...

Page 11: ...pace for easy inspection and maintenance Locate the pump as close to the suction source as possible to allow for the shortest and most direct routing of the inlet piping 4 2 Mounting Pump to Foundation and Power Source The W11 model pumps described in this document must be mounted in a horizontal position only Secure the pump to the mounting surface using the four 4 holes provided in the pump base...

Page 12: ...ion pulsation dampener is recommended to reduce the effects of acceleration head to help when suction conditions are not optimal In some cases it may be necessary to install a booster pump in the suction line to obtain sufficient pressure for the pump to operate satisfactorily The suction line must be configured so there are no high spots in the line where air pockets can collect These pockets may...

Page 13: ... the hose Working pressure ratings for steel pipe can be obtained from the manufacturer or from the chart shown in Table 1 2 Always use a pressure gage in the pump discharge line A properly functioning gage mounted at the pump and before any valves is required to accurately determine the operating pressure of a pump and to conduct troubleshooting 3 Ensure that all piping is supported independently...

Page 14: ...ischarge line must be as large as the pipe outlet of the relief valve Never install valves in the relief valve discharge line or between the pump and relief valve FMC recommends that the discharge be returned to the tank or drain not back into the pump suction line 5 It is recommended that a start up bypass line and valve is installed to allow flow to bypass the relief valve This allows the pump t...

Page 15: ...ibility of the operator to determine the correct start up procedure for each installation 1 Ensure that the drain plug s on the bottom of the pump crankcase have been installed and are tight Ensure that the oil level sight glass if equipped has been properly installed 2 Check the oil level to ensure that the pump is properly filled with non detergent motor oil or a synthetic oil as described in Ta...

Page 16: ...and tagged out Turn the pump over by hand if possible to ensure free unobstructed operation 7 Apply 10 to 20 drops of glycerin or mineral oil to the pistons cylinders and piston rods to lubricate the packing and seals 8 Make sure that all guards are in place and secure Verify that all personnel are in safe positions and that system conditions are suitable for operation 9 The pump is now ready to s...

Page 17: ...Consult FMC for lubrication recommendations for applications that fall outside of the conditions listed in Table 2 below NOTE Lubricant temperatures should not exceed 170 F 77 C for continuous duty or 180 F 82 C for intermittent duty applications on W11 pumps Crankcase temperatures that exceed these limits will cause the mineral based lubricant to prematurely break down The result will be poor lub...

Page 18: ...ein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI Table 2 W11 Recommended Lubricants Synthetic lubricants are suggested for high or low temperature service Cortec is a registered trademark of Cortec Corporation St Paul MN ...

Page 19: ...or severe or unusual operating conditions Table 3 W11 Maintenance Schedule Interval Component Service Remarks Break In Crankcase Oil Change Drain and refill with new oil after first 100 hours of operation Ensure that the magnetic drain plugs are cleaned to remove debris Period Inlet Strainer Inspect Clean if Required The amount of material in the strainer will determine the interval of cleaning Co...

Page 20: ... to facilitate maintenance schedules and stocking of spare parts The maintenance of the power end lubrication system will influence the life of the power end components The speed of operation and percent of maximum allowable load will influence the life of both power end and fluid end parts The temperature abrasiveness and lubricity of the liquid affect the life of fluid end expendables POWER END ...

Page 21: ...0 Component Parts List A typical pump configuration is shown below for general reference purposes This will aid in identifying components for service procedures outlined in the following sections Each W11 pump may have a slightly different appearance To order service parts or see exact component configurations for your particular pump refer to the cross section parts drawing in the literature kit ...

Page 22: ... Connecting Rod 3 4 Rod Bearing 6 5 Wrist Pin 3 6 Crosshead Assy 3 7 Seal Holder 3 8 Oil Seal 9 9 Bearing Housing 2 10 Bearing Housing Gasket 2 11 Shim 6 12 Back Cover 1 13 Back Cover Gasket 1 14 Oil Cap 1 15 Bearing Cone 2 16 Bearing Cup 2 17 Pinion Shaft 1 18 Pinion Cap 1 19 Pinion Bearing Cap 1 20 Pinion Shaft Roller Bearing 2 21 Pinion Gasket 2 22 Pinion Oil Seal 1 23 Wiper Seal Pinion Nut 3 2...

Page 23: ...ons to the contrary this document and all the information contained herein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI Figure 3 Fluid End Components ...

Page 24: ...ck Not Shown 1 49 O Ring 3 50 Piston Cup Nut 3 51 Valve Cover Clamp Nut 6 52 Fluid Cylinder Nut 8 53 Piston Assy Nut 3 54 Discharge Port Plug 1 55 Fluid Cylinder Drain Plug 6 56 Suction Port Plug 3 57 Valve Cover Stud 6 58 Fluid Cylinder Stud 2 59 Cylinder Cover Stud 6 60 Valve Cover Washer 6 61 Cylinder Cover Washer 6 Some piston holders are grooved for the o ring others require a seal holder sit...

Page 25: ...igure 3 for locations of components WARNING Many accidents occur every year through careless use or service of mechanical equipment You can avoid hazards associated with high pressure equipment by always following the safety precautions listed in Section 1 0 10 1 Replacing Cup Pistons FMC W11 pumps are available with two different types of piston cups pictured to the right See Service Tips for ins...

Page 26: ...ding the cylinder cover clamps in place and then remove the cylinder covers 41 If the cylinder covers are stuck to the fluid cylinder 34 insert a flathead screwdriver or small pry bar to pry off the cylinder covers see picture to the right Do not remove the two nuts on the short studs on opposite corners of the fluid cylinder as they keep the cylinders 37 and fluid cylinder mounted on the pump dur...

Page 27: ...hout referencing the Service Tips below Service Tip To perform service on W11 pumps equipped with Type B pistons the fluid end must be removed and the liners must be taken to a bench or other work area for assembly Follow the steps outlined in Section 10 2 Removing the Fluid Cylinder for information about this procedure Service Tip Piston assemblies in W11 pumps must be installed in the piston lin...

Page 28: ... piston rod seals Refer to Figure 3 for illustration of parts NOTE FMC recommends that a sufficient quantity of clean water is pumped through the fluid end before starting any service procedures that involve fluid end components This will remove most contaminants left in the fluid cylinder by normal pumpage and improve the ability to work with parts or see potential problems CAUTION ENSURE THAT TH...

Page 29: ...ake care to ensure that the cylinders do not fall off of the front of the power end and become damaged 4 To remove the piston assemblies refer to steps 3 through 7 of the previous section 5 Inspect all parts for signs of wear or damage Replace parts as necessary in accordance with the previous section 6 Always replace the cylinder gaskets 47 when the cylinders have been moved or replaced 7 Reverse...

Page 30: ...e bottom of the fluid cylinder 34 3 Remove the six valve cover nuts 51 holding the valve cover clamps 46 and then remove the three valve covers 44 from the fluid cylinder 4 The cylinder covers 41 on W11 pumps allow access for inlet valve removal For these pumps remove the cylinder covers as described in Section 10 1 5 For ball valves the balls are not attached to the valve seat The ball can easily...

Page 31: ... the valve cover washers 60 if installed and the valve cover hex nuts 52 if any of these parts are visually deformed 8 Torque the valve cover hex nuts or hex plugs to the recommend values listed in the Fastener Torque Requirements Section 11 0 below 10 3 1 Valve Assembly and Knock Out Tool The simplest of the tools is the removal and installation tool part number P534695 small ball For disc valves...

Page 32: ...o care must be taken to avoid injury or damage to the tapered seat in the tool is not properly positioned against the bottom of the valve seat 10 3 2 Replacing W11 Disc Type Valves The disc type valve used in W11 FMC pump models is shown in Figure 5 The standard construction of stainless steel seat disc and stop are a relatively simple design with excellent performance and ample life These valve a...

Page 33: ...ools There are two Knock Out tools available for removing valves from W11 pumps The P534695 Small Ball Knock Out tool is the preferred tool for W11 pumps with ball valves The P534694 Large Ball Knock Out tool is designed for the disc valves in the W11 pumps The valves and appropriate tools are listed in Table 9 Figure 6 Illustration of the P534694 or P534695 Ball Valve Knock Out Tools All Knock Ou...

Page 34: ...a clean cloth Small scratches can be removed with steel wool or 100 grit emery paper Remove all dirt grease oil water or any other contaminants from the surfaces Do not oil the seats or the seating surfaces in the fluid cylinder Confirm they are dry before installation 3 Position the valve assembly directly over the mating taper in the fluid cylinder 4 Let the valve assembly drop into the taper Ch...

Page 35: ... of the piston rods The fluid end and cylinders must be removed as outlined in the previous sections to provide access to these seals 2 Rotate the seal retainer 23 counter clockwise until it is unthreaded from the frame then slide off the rod Use a screwdriver and mallet to unthread this seal retaining nut similarly to the example pictured to the right 3 Pull the seal holder 7 out of the pump fram...

Page 36: ...od 7 Ensure that the gasket 24 and seal holder 7 are in place install the seal retainer 23 and tighten until it bottoms out Do not over tighten as it can damage the seal retainer gasket 8 Remove the protective material that is covering the rod threads Rebuild the remainder of the pump as outlined in previous sections Torque all fasteners as outlined in the Fastener Torque Requirements Section 11 0...

Page 37: ...entation when reassembling the pump 5 Remove the pinion shaft bearing housing hex head cap screws 29 the left and right pinion housings 18 and 19 and pinion gaskets 21 from the power frame The gaskets may adhere to the power frame surface and can be left in place if they are not damaged It may be necessary to tap on the housings with a rubber mallet to free them from the pump frame 6 The pinion sh...

Page 38: ...p the crankshaft end on the right out the back of the power frame and remove The crankshaft should be handled carefully to prevent the critical bearing surfaces from being scratched or damaged 11 Bearing cones 15 may be removed from the crankshaft using an automotive type bearing puller Bearing cups 16 can be removed from the bearing housing using a puller if a sufficient lip is available for the ...

Page 39: ...eld in position until it cools enough to grab the shaft Use a 001 thick feeler gauge to ensure the cone is fully seated against the shoulder after parts have cooled 19 Use a press to seat the new cups 16 into the bearing housings Never use new bearing cones with old bearing cups Always use matched sets from one manufacturer 20 Reassemble the crosshead assemblies and connecting rods Ensure that the...

Page 40: ...st be used to properly adjust the endplay of the crankshaft Improper adjustment may result in excessive temperature noise and reduced bearing life FMC recommends between 002 tight to 003 loose of internal axial clearance end play when properly assembled The final adjustment must be verified using a dial indicator as indicated in the following steps 26 Turn the crankshaft more than two revolutions ...

Page 41: ...he crankshaft several turns and repeat the effort to move the crankshaft in the direction described in this step Repeat the dial indicator measurement Remove or add shims as necessary to achieve proper endplay 002 tight to 003 loose Distribute shims equally on both bearing housings Verify the endplay with the dial indicator per this procedure described before final assembly 31 Install the piston r...

Page 42: ...nds Ft lb and Newton meters N m Typical sizes are shown in Table 6 below Refer to Table 7 for other sizes that may be used depending upon application Table 6 Torque Values for Critical Pump Fasteners POWER END Item Component W11 No Description Size Ft lb N m 3 Connecting Rod Bolts 0 500 65 88 23 Piston Assembly Nut 0 750 35 47 53 Piston Rod Hex Nut 0 500 35 47 29 Bearing Housing Screws 0 500 60 81...

Page 43: ... clearance is allowed for component wear This additional clearance is a maximum of 002 inches of total diametric wear that can be added to the clearance values in Table 8 For radial clearance use of the total diametric value Table 8 Clearance Chart DESCRIPTION W11 Crankshaft Throw Diameter Stroke 2 75 Crankshaft Pin or Journal OD 3 4990 3 4995 Connecting Rod Crank Clearance Max Total 0 003 Crosshe...

Page 44: ...tten authorization by FMCTI 13 0 Special Service Tools Table 9 Special Service Tool Guide W11 PUMPS Valve Installation and Removal Tools TYPE ASSY PART No SIZE REMOVAL TOOL INSTALLATION TOOL Disc 1278104 1 563 G L 1 09 ID P534694 Large Ball P534694 Large Ball and P534699 Small Valve Tool Ball 1284740 1 563 G L 937 ID P534695 or P534694 Large Ball P534695 Small Ball Piston Servicing Tools W1122 All...

Page 45: ...relief valve and adjust setting Properly service system Inspect check valves and repair or replace Adjust or replace packing or damaged parts Insufficient flow from pump ONLY Pump speed is too low Relief valve improperly adjusted or worn Worn pump valves Excessive leakage from pump seals Plunger or piston worn Valve seat washed out in fluid cylinder Check belt tightness or power to motor Check rel...

Page 46: ... elbows or tees See above Install discharge pulsation dampener Install supports at proper locations Correct installation to minimize turns and short radius fittings Pump requires excessive power Discharge pressure too high Plungers or pistons too large Speed too high Packing too tight Misaligned coupling Belts too tight Power end bearings too tight Low motor voltage Reduce system back pressure or ...

Page 47: ...rect problem and replace damaged valves Correct problem and replace damaged valves Increase submergence or baffle to stop vortex Pipe back to reservoir tank Replace damaged components Cracked fluid cylinder or broken fluid end bolts Discharge pressure too high Hydraulic shock cavitation or entrained air Discharge valve stuck closed Fluid freezing in fluid cylinder Material or manufacturing defect ...

Page 48: ...ice for the location of an authorized parts retailer in your area Always insist on genuine FMC replacement parts Use the assembly drawing and bill of material included with this manual to determine the components and corresponding part numbers required to service the pump Make sure that the part number on the drawing or bill of material matches the part number of the pump requiring parts When plac...

Page 49: ...s in the chamber between the suction and discharge valves during the suction stroke and often sounds like a mechanical knock Cavitation results in the formation of gas bubbles or cavities in the fluid that cause vibration and damage to components when they collapse DAMPENER A device that reduces pressure pulsations in the suction or discharge piping This may be referred to as a suction stabilizer ...

Page 50: ...he system at the pump suction connection minus the vapor pressure of the liquid at actual pumping temperature NPSHA for a reciprocating pump is normally expressed in units of feet of water NPSHr An abbreviation that stands for Net Positive Suction Head Required This is the minimum total inlet pressure required by the pump for proper operation This value is a function of pump design and speed and i...

Page 51: ...press written authorization by FMCTI POWER FRAME The major portion of a power pump that encloses and supports all other components of the power or drive end It is called a pump case in old literature STROKE LENGTH The length of one complete unidirectional motion of the piston or plunger Stroke length is usually expressed in inches PUMP VALVE A check valve that allows flow of liquid in one directio...

Page 52: ...nformation such as part and serial numbers will be needed when ordering service parts This data may be found stamped on the metal nameplate located on the pump power frame This area may also be used to make notations about special parts procedures phone numbers or other important information related to your pump Pump Model ________________________________________ Part Number ______________________...

Page 53: ...ry this document and all the information contained herein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI 18 0 MAINTENANCE LOG DATE SERVICED BY SERVICE PERFORMED REMARKS ...

Page 54: ...rms and conditions to the contrary this document and all the information contained herein are the confidential and exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMCTI ...

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