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Doc. No.: OMS500000104
Rev: A Page 1 of 42

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 FMC.

OPERATION, MAINTENANCE, & STORAGE PROCEDURE

M28 MANUAL

Rev

ECN No.

Date

Reviewed By

Approved By

Status

A

5011457

30-Jan-04

Storey, Bryan T.

Herold, John R.

RELEASED

Summary:

This is an operations, storage and maintenance manual for an M28 pump. The M28 is a seven
inch stroke triplex positive displacement pump.

Summary of Contents for M28

Page 1: ...gies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMC OPERATION MAINTENANCE STORAGE PROCEDURE M28 MANUAL Rev ECN No Date Reviewed By Approved By Status A 5011457 30 Jan 04 Storey Bryan T Herold John R RELEASED Summary This is an operations storage and maintenance manual for an M28 pump The M28 is a seven inch stroke triplex positive dis...

Page 2: ...t Term Storage 7 3 2 Short Term Storage for Severe Environments 7 3 3 Long Term Storage 7 3 4 Precautions during Freezing Weather Conditions 8 4 0 Installation Guidelines 9 4 1 General Location 9 4 2 Mounting Pump to Foundation and Power Source 9 4 3 Suction Piping Recommendations 9 4 4 Discharge Piping Recommendations 10 4 5 Multiple Pump Systems 11 5 0 How to Start a Pump 12 6 0 Recommended Lubr...

Page 3: ...he 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 FMC 10 0 Fastener Torque Requirements 33 11 0 Special Service Tools 34 12 0 Trouble Shooting Pumps 36 13 0 Ordering Parts 39 14 0 Glossary of Commonly Used Terms 40 15 0 Reference Information 42 ...

Page 4: ...xpress written authorization by FMC List of Figures Figures Page Figure 1 Power End Components 15 Figure 2 Fluid End Components 16 Figure 3 Plunger Packing Replacement 20 Figure 4 Cylinder Cover Removal 21 Figure 5 Removal of Fluid Cylinder 23 Figure 6 Oil Seal Replacement 25 Figure 7 Back Cover Removal 27 Figure 8 Power End Disassembly 28 Figure 9 Crank Shaft Bearing Removal 29 Figure 10 Cranksha...

Page 5: ...rate the pump without a pressure relief valve burst disc or other type of properly sized overpressure 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 Insure that no valves are placed between the pum...

Page 6: ...spline for direct coupling of hydraulic motor drives Magnetic drain plugs remove tramp iron from the oil bath State of the art plungers and packing provides unmatched service life in even the toughest applications Integrally cast and machined feet to provide rigid and precise mounting Individual clamped cylinder covers allow removal of plungers through the front of the fluid cylinder Abrasion resi...

Page 7: ...fluid end should be drained flushed with water or other non corrosive cleanser and blown dry using compressed air whenever idle 3 2 Short Term Storage for Severe Environments 1 Drain any fluid from pump flush the fluid end with water to clean out any of the remaining pumpage and blow dry with compressed air Spray a fog of preservative oil into the suction and discharge ports of fluid end then inst...

Page 8: ...these steps have been completed follow the normal pump start up procedures outlined in this manual FMC can factory prepare units for extended storage for a nominal fee if specified at the time of order 3 4 Precautions during Freezing Weather Conditions 1 Freezing weather can cause problems for equipment when pumping water based fluids that expand in volume when changing from a liquid to a frozen s...

Page 9: ...ration 2 For units that are V belt driven check the alignment of the sheaves after the unit is installed on its permanent mounting Tighten belts to the proper tension as recommended by the belt manufacturer Verify that the sheaves are in line and running parallel to each other with a straight edge or other device Never operate the pump without the belt guard securely in place 3 For direct coupled ...

Page 10: ... of flexible hose connections between the pump and any rigid piping 5 Always insure that calculated system net positive suction head available NPSHa exceeds pump net positive suction head required NPSHr by at least 5 feet 1 5 meters of water for proper operation of the pump NPSH requirements for each pump model are provided on the product data sheets available through FMC or you authorized FMC res...

Page 11: ...To help isolate mechanical and hydraulic vibrations FMC recommends the use of flexible hose connections between the pump and any rigid piping or the use of pulsation dampeners 4 A properly adjusted pressure relief valve or rupture disc must be installed directly downstream of the pump to prevent damage or injuries resulting from over pressure or deadhead conditions The relief valve by pass line mu...

Page 12: ...glass has been properly installed 2 Check the oil level to insure that the pump is properly filled and that the oil has not been contaminated with water or other liquids FMC pumps are not shipped with oil in the power frame and must be filled with the proper grade of oil prior to start up The M28 pump requires 13 gallons 49 2 liters of oil Use the chart provided in Section 6 for assistance in sele...

Page 13: ...r an endorsement of any particular product or manufacturer Consult FMC for lubrication recommendations for applications that fall outside of the conditions listed below Recommended Lubricant Chart Type of Service Ambient ISO Grade AGMA SAE SSU Temperature cSt Number Weight Viscosity Brand Names General Service 0 95º F 100 3 30 550 Texaco Meropa 100 Shell Omala 100 Shell Rotella T SAE 30 Exxon XD 3...

Page 14: ...schedule maintenance The chart shown below should be used as a guideline only Many applications will require adjustment of the intervals shown in this chart for severe or unusual operating conditions Interval Component Service Remarks Break In Period Crankcase Oil Change Drain and refill with new oil after first 50 hours of operation Insure that magnetic drain plugs are cleaned of debris Inlet Str...

Page 15: ...uration is shown below for general reference purposes for service procedures outlined in the following sections Actual pumps supplied by FMC may use slightly different components or configurations To order service parts or see exact component configurations for your particular pump refer the cross section drawing in the literature kit supplied with the pump Contact your OEM reseller or FMC if you ...

Page 16: ...erein 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 FMC 65 50 55 59 40 76 67 61 48 56 78 77 79 63 62 53 75 67 74 47 68 71 38 39 52 51 58 69 64 54 41 73 72 73 49 65 55 59 42 57 60 70 66 43 45 46 44 Figure 2 Fluid End Components ...

Page 17: ...ousing 1 8 Bearing Housing 1 9 Shim As needed 10 Back Cover 1 11 Bearing Cup 2 12 Bearing Cone 2 13 Rod Bearing 6 14 Back Cover Gasket 1 15 Plunger Clamp Assembly 3 16 Seal Housing 3 17 Cap Screw Seal Housing 12 18 Lock Washer 12 19 Cap Screw Bearing Housing 12 20 Cap Screw Back Cover 28 21 Set Screw 3 22 Set Screw 3 23 Deflector Shield 3 24 O ring Seal Housing 3 25 O ring Bearing Housing 2 26 U C...

Page 18: ... 51 Valve cover 3 52 O ring Valve Cover 3 53 O ring Suction Manifold 3 54 O ring Stuffing Box 3 55 O ring Discharge Flange 2 56 Gasket 1 57 Stud Fluid Cylinder 4 58 Stud Valve Cover 12 59 Stud Discharge Flanges 16 60 Stud Stuffing Box Clamp 12 61 Stud Suction Flange 8 62 Stud Suction Manifold 12 63 Lock Nut 4 64 Hex Nut Valve Cover 12 65 Hex Nut Discharge Flanges 16 66 Hex Nut Stuffing Box Clamp 1...

Page 19: ...fluid cylinder by the normal pumpage and improve the ability to work with the parts or spot potential problem areas Refer to the following page for the position of parts 2 Bleed off all pressure inside pump fluid end before starting any service work Shut the valve on the inlet piping if provided to prevent flow of liquid from the source into the pump during service CHECK TO INSURE THAT THE POWER I...

Page 20: ... 76 With the covers off remove the plungers 46 by pulling them out through the front of the fluid cylinder 38 The stuffing box assemblies can then be removed through the cradle area of the pump The advantage to this process is that the stuffing box assemblies are much lighter with the plungers removed 7 Inspect all parts for damage or unusual wear patterns and replace any components that appear da...

Page 21: ...written authorization by FMC 8 Reverse the previous steps to rebuild the pump after worn or damaged components have been replaced FMC recommends that all seals or gaskets that are disturbed during a service procedure be replaced This includes the stuffing box face seal o ring 54 cylinder cover o rings 75 and valve cover o rings 52 Insure that all fasteners are tightened to the values specified in ...

Page 22: ...re started This action will remove a significant portion of contaminants left in the fluid cylinder by the normal pumpage and improve the ability to work with the parts or spot potential problem areas 3 Bleed off all pressure inside pump fluid end before starting any service work Shut the valve on the inlet piping if provided to prevent flow of liquid from the source into the pump during service C...

Page 23: ...hat if the lock nuts 63 on the fluid cylinder studs 57 are not adequately torqued a failure is highly likely 9 3 Replacing Plunger Rod Oil Seals 1 The plunger rod oil seals retain oil in the power frame 1 and prevent dirt water or other contaminants from entering the power frame 1 by way of the plunger rods The fluid end need not be disturbed to perform this procedure 2 Bleed off all pressure insi...

Page 24: ...ote the orientation of each seal prior to removing it 8 Inspect the plunger rod 6 at this time If it is scored or damaged in any way it must be removed To remove the plunger rod 6 unscrew it from the crosshead 5 A new plunger rod 6 is screwed into the cross head 5 and torqued per the Fastener Torque Requirements section of this manual 9 Install a new o ring 24 and new seals 26 in the seal housing ...

Page 25: ...e 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 FMC 15 6 17 18 26 26 24 Figure 6 Oil Seal Replacement ...

Page 26: ...linder Remove the covers 51 4 For AR type valves refer to MSP500000080 This document describes the methods for removing and installing the AR valves 5 For disc type valves refer to MSP500000081 This document describes the methods for removing and installing disc valves 6 After the valves have been replaced inspect the o ring 52 on the valve cover 51 FMC recommends that the valve cover o rings 52 b...

Page 27: ...t these parts sometimes adhere to the crankshaft pin 2 6 Connecting rods and caps are matched sets and must always be reassembled with their original mate and in the same orientation Note the numbered codes stamped on each half of the connecting rod assemblies and make certain they are installed as matched set and in the same orientation when re assembling the pump 7 Unbolt the four cap screws 17 ...

Page 28: ...blind side bearing housing 7 hex head cap screws 19 and shims 9 Remove the drive side bearing housing 8 hex head cap screws 19 and shims 9 Note that the bearing cups 11 and crankshaft oil seal 27 will remain attached to the bearing housing 8 It may be necessary to tap on the housing with a rubber mallet to free it from the power frame 1 after the hex head cap screws 19 have been removed If that is...

Page 29: ...this purpose as the typical crankshaft weighs nearly 600 pounds The throws may have to be rotated as the crank is removed to clear the connecting rods The crankshaft should be handled very carefully to prevent the critical bearing surfaces from being scratched or damaged 11 Bearings cones 12 can be removed from the crankshaft 2 using an automotive type bearing puller Bearing cups 11 can be removed...

Page 30: ... FMC 12 12 2 A Figure 10 Crankshaft Removal 12 Pull connecting rod and crosshead assemblies from the power frame 1 Take care to insure they are reassembled into the same bore from which they were removed 13 Inspect all components for signs of wear or damage and replace if required Carefully check the crankshaft bearing surfaces for pits scratches or other signs of wear If any of the bearings are d...

Page 31: ...ls enough to grab the shaft Use a 001 thick feeler gauge to insure the cone 12 is fully seated against the shoulder after parts have cooled 17 Use a press to seat the new cups 11 in the bearing housing 7 8 Never use new bearing cones 12 with old bearing cups 11 18 Reassemble the crosshead assemblies 5 and connecting rods 3 Install new rod bearing inserts 13 Insure that the set screws 21 22 retaini...

Page 32: ...tions to insure the connecting rods are loose there is no binding in the rod bearings the wrist pin joints are free and the crossheads move freely in the power frame 1 25 Mount indicator base on back of power frame 1 with the indicator tip on a shoulder of the crankshaft 2 and the axis of the indicator parallel to the crankshaft 2 26 Move the crankshaft 2 to one side of the power frame 1 using a l...

Page 33: ...0 Back Cover Bolts 0 500 13 UNC GR 5 40 54 19 Bearing Housing Bolts 0 750 10 UNC GR 5 130 176 3 Connecting Rod Bolts 0 625 18 UNF A193 B7 150 203 21 22 Cross Head Set Screw 0 375 16 UNC Alloy 20 27 17 Seal Holder Cap Screw 0 375 16 UNC GR 5 25 34 32 Cradle Cover Wing Nuts 0 375 16 UNC GR 2 25 34 6 Pony Rod to X Head 2 000 12 UN 17 4 PH 450 610 15 Pony Rod Plunger Clamp 0 750 10 UNC 18 8 SST 95 129...

Page 34: ...exclusive property of FMC Technologies and may not be reproduced disclosed or made public in any manner prior to express written authorization by FMC 11 0 Special Service Tools The items listed below are special tools available from FMC to help aid in key service procedures They are referenced in several of the proceeding maintenance procedures A Figure 12 Crankshaft Lifting Tool ...

Page 35: ...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 FMC Valve removal kits Pump Models AR Style Disc Style Valve Series M2816 M2818 5276358 8 M2820 M2826 9 M2830 M2834 P511484 10 11 M2836 M2842 P511484 12 M2844 M2850 P518342 20 25 ...

Page 36: ...ONLY Pump speed is too slow Relief valve improperly adjusted and by passing fluid Oversize or worn nozzle on equipment Worn pump valves Excessive leakage from pump seals Insufficient flow from pump ONLY Pump speed is too slow Relief valve improperly adjusted and by passing fluid Worn pump valves Excessive leakage from pump seals Insufficient flow OR pressure AND rough operation Valve problem 1 Pum...

Page 37: ...e wearing and about to fail Fluid cylinder bolts are not properly tightened Fluid cylinder o rings or gaskets are damaged Piston assembly o rings are damaged Short piston seal life High abrasive particle content in fluid Wrong style or type of piston for service Piston liner is damaged Pump is cavitating cylinders may run hot Piston assembly o ring is damaged Poor quality water used sources like l...

Page 38: ...aminated power end oil Pump speed is too fast Pump is running backwards Couplings are misaligned V belt drive tension is too tight Pump located too close to heat source Worn or damaged power frame bearings Broken crankshaft or connecting rod Pump exposed to freezing conditions without proper draining Discharge pressure too high Suction pressure too high Hydraulic shock due to cavitation Material o...

Page 39: ... the location of an authorized parts retailer in your area Always insist on genuine FMC replacement parts Use the assembly drawing and bill of materials 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 materials matches the part number of the pump requiring parts When ordering ...

Page 40: ...ubbles or cavities in the fluid that cause vibration and damage when they are collapsed by the increased fluid pressure on the discharge stroke D A M P E N E R A device that reduces pressure pulsations in the suction or discharge piping This may be referred to as a suction stabilizer accumulator or surge suppressor D I S P L A C E M E N T The volume swept by all pistons or plungers per unit time T...

Page 41: ...s determined by the pump manufacturer through a specific NPSH test P I S T O N A type of power pump that uses a cylindrical seal piston mounted on a holder to drive fluid through the valves The piston seal reciprocates within a stationary cylinder P L U N G E R A type of power pump that uses a cylindrical element or plunger to drive fluid through the valves The plunger reciprocates through a stati...

Page 42: ...ion by FMC 15 0 Reference Information Use the following section to record key information about your specific pump model Information 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 importa...

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