HYDROSTATIC CORE DRILL

KDR 200
CRAWLER MOUNTED

KORES INDIA LTD

ENGINEERING DIVISION
PLOT NO : 6, AREA NO. 1,
PITHUMPUR 454775 , DIST: DHAR , ( M.P.)
PHONE NO : -07292-252275, FAX NO :- 07292-253378
HYDROSTATIC CORE
DRILL
KDR 200
CRWLER MTD

PARTS AND SERVICE

MANUAL
 CONTENTS

( 1 ) SECTION-I : OPERATING & MAINTENANCE MANUAL

( 2 ) SECTION-II : PARTS MANUAL

( 3 ) SECTION-III : SPT PARTS MANUAL

( 4 ) SECTION-IV : CRAWLER MANUAL

( 5 ) SECTION-V : MUD PUMP MANUAL

 SECTION – I
OPERATING &
MAINTENANCE
MANUAL
 TABLE OF CONTENTS

PAGE NO.

( 1 ) A WORD OF CAUTION 01

( 2 ) TO THE OPERATOR 02

( 3 ) GENERAL DESCRIPTION 03

( 4 ) CONTROL & INSTRUMENTS 04

( 5 ) OPERATING INSTRUCTIONS 14

( 6 ) LUBRICATION & MAINTENANCE 17

 CAUTION

1. WEAR HARD HATS AT ALL TIMES.

2. DO NOT WEAR LOOSE CLOTHING.

3. CONFINE LONG HAIR.

4. PLACE ALL CONTROLS IN NEUTRAL BEFORE STARTING.

5. LEVEL MACHINE BEFORE RISING.

6. STAY CLEAR OF ROTATING PARTS AND DRILL STRING.

7. KEEP CONTROLS AND WORK AREAS CLEAR OF GREASE, OIL AND DEBRIS.

8. SHUT DOWN POWER UNIT WHEN SERVICING & REFUELING.

9. CHECK LOCATIONS OF OVERHEAD AND UNDER GROUND POWERLINES AND

PIPELINES.

10. DO NOT OPERATE HOISTING DRUM WITH LESS THAN 2 WRAPS OF WIRE

ROPE.

11. OPEN ALL SUCTION VALVES BEFORE STARTING THE MACHINE.

- 01 -
2. TO THE OPERATOR:

This manual contains descriptive material to enable the operator to under- stand the operation, basic
maintenance, and necessary safety precautions for the kdr 200 . It is of vital importance in obtaining
maximum performance, safe and trouble free operation that the maintenance and adjustment
procedures outlined in this manual be carried out properly and on schedule.

The operator should familarize himself thoroughly with the contents of this manual, as well as the
manufacturer’s operator’s manual for the power unit engine, before attempting to operate the unit or
carry out maintenance or adjustment procedures.

All safety precautions outlined in this manual should be followed at all times. Remember, any
equipment is only as safe as the person who is at the controls; think before you act.

Although many drilling operations can be effectively handled by one person, safety precautions dictate a
second driller or helper. However, both people must be trained in the use of all equipment on the job and
completely familiar with each other’s job functions. The actions of one person may directly affect the
safety of the other.

If at any time a question arises which is not covered by this manual, call or write the factory where
the kores service department will be glad to help you.

- 02 -
3. GENERAL DESCRIPTION:

The kdr 200 is a hydraulic, rotary drill designed for use with spt. The kdr 200 can be trailer or
crawler mounted. It consists of a prime mover, rotary drill head and hydraulic system. The drill will
accommodate vertical holes and can be used for drilling, soil sampling diamond core drilling,
dewatering wells, exploration. Options include hydraulic and wire drum hoist, crown block, and
levelling jacks.

The hydraulic system consists of a open loop hydrostatic circuit for drill rotation, and for water pump,
feed, slide base operations and accessories such as hydraulic chuck, levelling jack, etc. Also included in
the system is a full flow filter, bit weight and feed speed regulators, directional control valves and
all necessary pressure piping and fittings.

The mast is fabricated of structural steel. It is raised from the horizontal travel position to vertical by
a hydraulic cylinder. Travel of the drillhead is accomplished by a double acting hydraulic cylinder and
wire rope system. A full 3.5 meter travel is provided.

A power activated slide base provides a 14” drill head movement on or off the hole.

The drill head rotation is powered by a fixed / variable displacement motor . All controls and
instruments are located in the control console at the left rear of the drill.

-03-
4. CONTROLS AND INSTRUMENTS:

Following is a description of each control and how it functions. Refer to the appropriate “operator’s
control console” drawing at the end of this section for either the trailer model or crawel model. For
complete operating instructions refer to the specific section under that title.

-04-
 CONTROL PANEL

ENGINE RPM
ENGINE OIL PRESSURE
ENGINE OIL TEMPERATURE
AMMETER
MAIN VALVE PRESSURE
AUXILIARY PRESSURE

UP MICROFEED DOWN
BIT WEIGHT
MICRO FEED

LIGHT IGNITION

RIGHT LEFT R MUD UP S FAST WIRE FOOT RACK J J J J UP

T T O P H P F L C S A A A A M
R R T U O T E I L L C C C C A
A A A M I E N A I K K K K S
C C T P S D E M D 4 3 2 1 T
K K I T P E DOWN
O DOWN
N

-05-
STARTER CRANK

See manufacturer’s operator’s manual before starting engine. Push the starter key to energize the
starter.

THROTTLE CONTROL

By operating the throttle lever push and pull engine speed can be varied.

POWER UNIT

Refer to the manufacturer’s operator’s manual for specific details on the power unit.

- 06 -
HYDRAULIC PUMP

POWER RATING : 103 HP

-07-
FEED SPEED REGULAR

This adjustable valve controls the rate at which the drill head feed cylinder pushes down the drill string.
Turning the knob clockwise decreases the feed rate. Feed can be stopped completely by turning the knob
clockwise as far as it will go. Turning the knob counter-clockwise increase the feed rate.

FEED CYLINDER

HYD MOTOR

SPINDLE

DRILL HEAD CASE

-08-
The valve controls the down feed rate by restricting the flow of hydraulic oil out of the feed cylinder.
When the drill head is being raised, there is no restriction of flow regardless of the valve setting.

DRILL HEAD FEED

The handle marked “feed” controls the direction of the drill head down the handle for down; up for up.

The feed spool by operating the handle to the top most position, the feed spool is in a “float” position
where gravity, acting on the drill head and drill string, determines the feed rate. This is a useful feature in
augering whereby the auger can determine it’s own feed rate.

FAST FEED

To achive fast feed operate the fast feed lever for up feed and down for down feed.

-09-
 CAUTION

Shut down power unit and service filter when indicator is in red or above 0.2 bar.

NOTE: Allow hydraulic oil to warm up before operating drill. Cold oil may give temporary high vacuum
condition.

DRILL-ROTARY

Pull the lever marked “rotary” to rotate the drill string clockwise; push for counter-clockwise.

ROTATION PRESSURE GAUGE

Gauge indicates hydraulic pressure applied to rotary motor.

CHARGE PRESSURE GAUGE (S)

One charge pressure gauge is provided to monitor the pressure in the hydrostatic pump loop operating
the drill rotation.

- 10-
 CAUTION

Always retract stinger immediately after completion of work in the hole. Failure to do so may result in
severe structural damage.

CAUTION

Do not operate drill while supported by hydraulic jacks- they are for levelling purpses only.
Use wooden planks or screw jacks for safety after levelling machine.

MUD / WATER PUMP

Down the control lever marked “water pump” to operate the pump; return to neutral to stop pump.

- 11-
 WINCH (HOIST)-03 TON

Down the lever marked “hoist” to play cable out; up to wind cable in.

HYD. MOTOR
HYD. PUMP
GEAR BOX

-12-
 CAUTION

Pump must not be operated dry. Turn the pump shaft five revolutions after draining for complete
evacuation.

MUD PUMP FLOW CONTROL

Operate knob anticlocewise to increase the mud or water flow.

HYDRAULIC ROD CLAMP

The hydraulic safety rod clamp is opened by down the hadle marked “hydraulic rod clamp”; and up the
hanle to close clamp.

- 13 -
5. OPERATING INSTRUCTIONS.

SET – UP

Be sure that all “assembly” instructions and “lubrication and maintenance”, as outlined in those
sections of this manual, has been done before operating the drill.

Be sure power unit has been properly serviced according to manufacturer’s manual.

The operator should be completely familiar with the operation of all controls as described under the
“control and instruments” section.

In starting up a new machine, run the machine at idle speed and try all controls until the operation of
them is familiar.

START – UP

1. Remove all mast lock pins and bolts.

2. Check that all control handles are in neutral position.

HYDROSTATIC PUMP START – UP

The following procedure is to be followed to ensure proper filling of all pumps, motors and lines. During
filling be certain oil level in reservoir, is sufficient to prevent air from being drawn into system.

1. Check all fittings to be sure they are tight.

2. Loosen the charge pump line at the inlet to the charge pump.

- 14 -
 HYDRAULIC TANK

CAPACITY : 400 LITERS

3. Fill the reservoir with approved oil. See “recommended lubricants” chart in lubrication and
maintenance section. When oil appears at the loosened hose at the charges pump inlet, tighten the hose
and continue filling the reservoir. Leave reservoir cap loose so air will escape.

4. Fill the pump case through the case drain opening with approved oil.

5. The pump must be in neutral. It is recommended that the control shaft arm be left disconnected
until after initial start – up.

6. Start engine, maintaining as low an idle as possible to allow oil to fill the main high pressure lines.
During this initial start – up, charge pressure surges and a slow rise will be seen on the 600 psi gauge.
 CAUTION

Keep mast clear of overhead electrical power lines.

CAUTION

Level and stabilize machine before elevating mast. Check for overhead obstructions and lower any
leveling jacks before erecting mast. Never drill extra pin holes in any support column or stiff leg.
Insert pin thru slide base and drill frame before elevating mast.
Insert pin through mast bracket and slide base, to drill an angle hole, follow steps while raising mast, the
bracket may be pinned at angle 9 0 degree
to vertical.

CAUTION

Mast must be in “feed up” position and jack retracted before operating slide base.

-16 -
6. LUBRICATION AND MAINTENANCE.

LUBRICATION AND MAINTENANCE CHART

COMPONENTS TIME INTERVAL
INITIAL TWICE AS
START-UP DAILY WEEKLY MONTHLY ANNUALY REQUIRED
CRAWLER REFER TO MANUFACTURER’S MANUAL
POWER UNIT
ENGINE
BATTERY A B
FEED ASSEMBLY C
MAST BRACKET G
ASSEMBLY
CROWN BLCK H
WIRE LINE HOST I I
HYDRAULIC A, J E N F
SYSTEM
DRILL HEAD D
MOTOR
DRILL HEAD D E F
CHAIN DRIVE
FOUR SPEED D E F
TRANS.
HYDRAULIC M
FILTERS
CRAWLER OPTION D
HYDRAULIC D
MOTOR
INTERMEDIATE D E F
DRIVE BOX

To obtain the best performance and long life from the kores kdr 200 , the operator must adhere to the
lubrication and maintenance schedule. The letters on the chart refer to the accompanying notes:

A. For overseas shipment, the kdr 200 is completely drained of all water, oil and fuel. Fill with
recommended fluids before attempting to operate. All exposed surfaces are coated with a rust
preventative prior to overseas shipment. This grease can be removed by wiping with a clean soft rag soaked
with a safety type cleaning solvent.
The battery is always shipped dry with the electrolyte shipped under separate cover.

-17-
 CAUTION
NOTE : extreme care should be used in handling this acid. Read all instructions on container carefully.

B. Check water level.

C. Wipe clean and lubricate with recommended grease.

D. Check for leaks and loose fittings.

E. Check oil level.

F. Drain, flush and fill each spring (sae 140) and fall (sae 90).

G. Lubricate grease fittings on each side of pivot pin and four (4) fittings located under slide base.

H. Lubricate grease fittings on sheave axles.

I. Oil drive chain daily. Lubricate (2) flange type pillow block bearings located on each end of hoist
shaft bi-weekly.
J. Fill to the top of the tank with recommended hydraulic oil. After running the machine to fill all
of the hydraulic lines, the tank should be refilled to mid-point of sight gauge. This space allows oil to
circulate through the lines and return to the tank.

K. Lubricate al grease fittings

L. Return line filters: - this is a single filter. Replace filter elements once every 1000 hours of operation
or 6 months, whichever comes first. In extremely dusty conditions, replace more frequently.

-18-
IN TANK STRAINER:-
Regularly remove and wash strainer in solvent (diesel fuel acceptable).

Intervals between element replacement and strainer washing will vary according to working conditions
and frequency of use.

FILTER FOR CHARGE PUMP: -

This filter is connected to a filter vaccum gauge. The indicator should read 3” to 5” or 0 – 0.2 bar when a
clean element is used.

CAUTION

When the indicator reads 10”/-0.2 bar vacuum the filter is dirty and needs replacing. Shut down power unit
and service filter.

A. Remove hydraulic reservoir drain plug each month and drain off accumulated condensation.

MISCELLANEOUS MAINTENANCE.

CHUCK JAWS

Should be cleaned periodically to remove accumulated dirt and grease.

FOLLOWER WAYS ON MAST

Keep clean and lubricate weekly with recommended grease. Under severe operating conditions (such as
down the hole hammer operations) clean and lubricate daily.

-19-
 OIL COOLER

HYD MOTOR

MODEL : 70 GPM OIL COOLER

RECOMMENDED LUBRICANTS:

(For additional details see kores equipment lubrication and amaintenance chart at beginning of
this section.)

RECOMMENDED LUBRICANTS

API LUBRICANT
COMPONENT CAPACITY SPECIFICATION
HYDRAULIC RESERVOIR 400 LITERS INDIAN OIL SERVO/
HP-HLP68
DRILL HEAD CHAIN DRIVE 12 LITERS SAE 90

MUD PUMP 5 LITERS SAE

30/40
WINCH 3 Ton 02 LITERS SAE 90

NON – ROUTINE MAINTENANCE

If questions should arise concerning service or repair of the kdr 200 drills, contact the kores (india)
limited. Service department who will be glad to assist. Kores (india) limited maintains an experienced
service crew who are available for world – wide field service.

ORDERING REPLACEMENT PARTS

Refer to the attached parts catalog, which pertains specifically to the machine no. Listed on the front cover,
for part numbers.

Please list: quantity, part number, connection, description, price, shipping address and routing.

Mail or wire all orders to kores (india) limited. (engineering division) plot no.6, area no-1, pithampur
454 775 dist - dhar (mp) telephone number
07292 - 252275, fax number 07292 - 253378.

Refer to the kores (india) limted general catalog for terms and conditions of sale.

-20-
 SECTION – II
PARTS MANUAL
-21-
-22-
-23-
-24-
-25-
-26-
-27-
-28-
SECTION – III
SPT PARTS
MANUAL
-29-
-30-
SECTION – IV
CRAWLER
MANUAL
TABLE OF CONTENTS

SERVICE INSTRUCTIONS – GENERAL .....................................................................….33

• FUNCTION OF UNDERCARRIAGE GROUPS ...............................................................……. 33
• CHECKLIST FOR UNDERCARRIAGE PARTS ..............................................................……. 34
• ENVIRONMENTAL PROTECTION.................................................................................………35
TORQUE CHART...........................................................................................................…..36
TRACK GROUP………………………………………………………………………………………………37
ROLLER GROUP .................................................................................................................39
• ROLLER GROUP RE-ASSEMBLY................................................................................…………..40
SPROCKET GROUP ........................................................................................................... 41
• DISMANTLING INSTRUCTION.................................................................................…………. 42
• ASSEMBLY INSTRUCTION..........................................................................................……..….. 43
TRACK TENSION ASSEMBLY………………………………………………………………………..44

-31-
CRAWLER TOP VIEW

-32-
 SERVICE INSTRUCTIONS
GENERAL FUNCTION OF UNDERCARRIAGE GROUPS

TRACK GROUP
• Provide a moving rail for the vehicle to run on.
• Transmit the driving force from sprocket to the Shoes.
• Support vehicle weight.
.ROLLER GROUP
• Guide and provide rolling of the vehicle on the moving rail.
• Support vehicle weight.
CARRIER ROLLER GROUP
• Guide and provide rolling of the track between sprocket & idler.
• Limit the sag / track tension for the tracks.
• Support track weight between sprocket and idler.
IDLER GROUP
• Guide and provide rolling of the track.
• Provide means of sag / track tension adjustment.
• Support vehicle weight intermittently.
• Absorb shock loads and reduce tension under mud-packing conditions, to
increase wear life of undercarriage.
SPROCKET GROUP
• Transmit driving force from final drive / gearbox to the track.
• Support vehicle weight intermittently.
DRIVE GROUP
•Convert the force of pressurized oil delivered from the pump into a rotational movement.

NOTES :

1) The machine should travel with idler in the front more frequently.
2) Ensure appropriate track tension at all times.
[Appropriate track tension is the minimum track tension required to move the machine without
slipping]
3) For quantities of parts used, please refer to the relevant parts book / parts list.

The above instructions/notes relate to all undercarriage groups in general.

Certain undercarriage groups or parts thereof may not be present/relevant in some track modules.

-33-
 CHECKLIST FOR UNDERCARRIAGE PARTS

Sr.
No. Check Item Criteria Method Frequency Remedy

1 ALL assemblies Missing parts Visual Inspn. Daily Repair or

/damaged parts replace

2 Roller Groups, Rotation Visual inspn by moving Daily Correct or

Carrier Roller the m/c to & fro replace
Groups, Idler
Groups
3 Machine u/c Mud packing Visual Inspn. Daily or weekly Clean with
(depending on water jet
underfoot
conditions)

4 Machine u/c- Track Hardware Tap the track bolt head Weekly
bolts &nuts loosening with a light hammer Retighten or
- Others along the axis. Daily
replace
Visual Inspn.

5 Roller Groups, Oil leakage Visual Inspn. Weekly Retighten

Correct and
Carrier Roller refill or
Groups, Idler replace
Groups
6 Track Tension Smooth Check for contact of Weekly Correct or
Assembly functioning piston with recoil assy replace
/ nitrogen cylinder

7 Machine u/c Track Use thread After repair or Correct and

alignment replacement ensure the
alignment

The above instructions/notes relate to all undercarriage groups in general. Certain undercarriage groups or parts
thereof may not be present/relevant in some track modules.

-34-
 ENVIRONMENTAL PROTECTION

A) Undercarriage groups contain lubricating oil; hydraulic track tension arrangement contains grease.These
petroleum products are environmentally hazardous as they can cause contamination of land.
Hence, proper care is necessary during disposal.
Disposal of used/waste oil or grease should be made in compliance with state and local laws and should be
entrusted to authorized persons or agencies.
In case of leakage pick-up free liquid / grease for recycle or disposal. Get the recycling done by authorized
contractors / agencies.

B) Undercarriage groups also contains seals which are rubber / plastic parts. Such parts can cause
contamination of land. Hence, proper care is necessary in their disposal.
Disposal of rubber / plastic parts should be made in compliance with state and local laws and should be entrusted
to authorized persons or agencies.

-35-
 TORQUE CHART

BOLT/SCREW TORQUE (N-m)

TO ASSEMBLE (± 5%)
UNDER CARRIAGE GROUP

TRACK GROUP TRACK SHOE & LINK ASSY @ 95 ± 20

OIL PLUG 10-14

TRACK ROLLER GROUP
ROLLER GROUP TO FRAME 96

OIL - PLUG 10-14

IDLER GROUP
YOKE TO IAWC 156

GREASE NIPPLE 60±10

CARRIER ROLLER GROUP TO
CARRIER ROLLER GROUP FRAME BRACKET 87

BOLT/SCREW TO TORQUE (N-m)

TRACK MODULE GROUP ASSEMBLE (+/- 15%)

DRIVE GROUP (TM07) DRIVE TO SPROCKET

DRIVE TO TRACK FRAME 155

Procedure to tighten Track bolts:

1) Lubricate bolt threads and washer face.

2) Tighten each bolt to the initial torque value given in the table.

3) Give each bolt additional rotation of 120º ± 5º to fully tighten it.

4) Track bolts are not be reused.

-36-
 TRACK GROUP

Straighten bent leg of the lock / split pin and

remove it, as applicable in TYPE-II.
1.

By means of appropriate similar devices

like guide (9) and driving pin (10) as shown
in the fig., hit out the master pin.

2. Remove track bolts and nuts to separate

out shoe from track link assembly.

Note: In case of bolt on rubber pads, first

remove the rubber pads by removing the
nuts from the studs.

-37-
 TRACK ADJUSTMENT - INSTRUCTION
1 The track adjustment should be done at site when
themachine is in its working environment. To
tension the track link assembly, make use of a
hand operated grease pump with a pressure
rating of around 140Kg/cm2 and drum capacity of
5 to 10 Kg. Connect the grease gun adaptor with
grease nipple of the hydraulic tensioner (5).
Operate the grease gun until the track link
assembly is tensioned.
Caution :( In case recoil mechanism is
used)The recoil spring assembly or
nitrogen cylinder assembly must not get
compressed while tensioning the track
link assembly.
2 If needed, release the pressure by loosening the
grease nipple at the hydraulic tensioner. Grease is
allowed to escape till the desired sag of the
track is obtained. Grease gun can be operated, if
required to get the desired sag.
3 After the tensioning is done, remove the grease
gun.
Caution :
While track tensioning check the following
critically :
Spring : – :( In case recoil mechanism is
used)
Ensure the compressed spring length is
maintained. The recommended value (SP) is as
indicated under respective IDLER GROUP
PARTS LIST / PARTS BOOK.
(Also refer to idler group instructions.)

4 Track link assemblies which are too loose, do not

fit properly on idler. They will slide, especially,
when driving forward or in

reverse. This sliding will cause a fast wear off

track link assemblies.
5 Track link assemblies which sit too tight will cause
increase in wear of idler bushings, drivbearings
and track link assembly pins and bushings.

-38-
 ROLLER GROUP

SR. NO. QTY. DESCRIPTION

1 1 ROLLER ASSEMBLY
2 1 ROLLER SHAFT
3 2 SEAL GROUP
4 1 STEEL BACKED BRONZE
BUSHING
5 1 ROLLER END COLLAR
6 2 SPRING DOWEL
7 2 SEAL O RING
8 1 PLUG
9 1 ROLLER END COLLER-PLUG SIDE

-39-
 ROLLER GROUP RE-ASSEMBLY

1. Clean all parts thoroughly and press the

bushings into the roller body in such a
way that oil grooves of the bushing stand
vertical, while the oil filling hole is
upright.

(Orientation of oil groove is not

important is oil hole is not on the
roller)

NOTE: Press capacity: 40 tons.

2. Place the Seal Groups in the

corresponding retainers at the roller
body and end collar.

Caution :

Do not interchange the metal-to-metal

seal pair.

NOTE : The rubber seals and all

surfaces that make contact with seals
must be clean and dry. Apply oil on the
rubbing metallic surfaces of Seal group’s
Seal Rings.

3. Connect shaft with one End Collar after

placing both seal-o-rings in the
corresponding grooves.

Caution :

Ensure that the oil flat (A) on shaft

shows in the same direction as the
mounting surface of end collar (B).
Ignore this instruction where flat on

shaft do not exists or the flat is existing

parallel to the dowel hole axis.

-40-
 SPROCKET GROUP

FIG.1

D1 & D2: DISMANTLING A1 & A2:

ASSEMBLY

-41-
 FIG. 2

D1 & D2: DISMANTLING A1 & A2:

ASSEMBLY

NOTE: FOR HARDWARE QTY. REFER “PARTS BOOK

-42-
 DISMANTLING INSTRUCTIONS

1. Release the Track Chain separate the Track. (Refer Track Group section)

2. Clean all parts and loosen the Bolts of Track Sprocket crosswise.
Remove the Bolts and pull out the Track Sprocket with safe & appropriate Lifting device.

3. Check for replacements of the Segments/Adaptor/Hardware.

4. Loosen the Bolts of the ' Gear Box crosswise.

Remove the Bolts and pull out the Gear Box using a safe & appropriate Lifting device.

ASSEMBLY INSTRUCTIONS

1. Clean all mounting surfaces of Gear Box/Frame thoroughly. Lift the Gear Box with safe &
appropriate Lifting device and carefully place it in the locating bore of the Frame.

2. Fix the Bolts & washers and tighten crosswise all the Bolts using Torque drench.

3. Clean all mounting surfaces of Gear Box/Sprocket properly. Lift the Sprocket with safe &
appropriate Lifting device and carefully place it in the locating flange of the Gear Box.

4. Fix the Bolts & washers and tighten crosswise all the Bolts using Torque Wrench.

5. Refer Track Group section for Track Assembly.

-43-
 TRACK TENSION ASSEMBLY

SR. NO. DESCRPITION

1 TRACK TENSION ASSEMBLY
2 SPRING
3 STUD RECOIL
4 SEAT SPRING
5 NUT RECOIL
6 LOCK
7 HEX BOLT
8 SPRING WASHER

-44-
SECTION – V
MUD PUMP
MANUAL
 Operation And Maintenance Manual
For AW1122 Pump
Summary:
This is a manual for American Mfg Company AW1122 triplex piston pumps.

Alternate model versions:

Disc Valve

The standard model AW1122D comes with left hand pinion shaft and square keyway shaft end.
Model AW1122D-R comes with right hand pinion shaft and square keyway shaft end.
Model AW1122D-SP comes with left hand pinion shaft with 14 tooth splined shaft end.
Model AW1122D-R-SP comes with right hand pinion shaft with 14 tooth splined shaft end.
Ball Valve

The standard model AW1122BCD comes with left hand pinion shaft and square keyway shaft end.
Model AW1122BCD-R comes with right hand pinion shaft and square keyway shaft end.
Model AW1122BCD-SP comes with left hand pinion shaft with 14 tooth splined shaft end.
Model AW1122BCD-R-SP comes with right hand pinion shaft with 14 tooth splined shaft end.

-45-
 AW11 Piston Pump Data

30 BHP Continuous Duty (36 BHP Intermittent Duty)

Specifications
Pump Model AW1118, AW1122
Configuration Horizontal Triplex Piston
Number of Pistons 3
Stroke Length 2.75 Inches (69.9 mm)
Frame Load Rating 6000 lbs. (2,721 kg)
Pump Weight 425 lbs. (197 kg)
Direction of Rotation Top of Shaft away from
Internal Gear Rotation 3.6:1
Intermittent Duty Speed 900 RPM (Jackshaft)
Continuous Duty Speed 750 RPM (Jackshaft)
Ball Valve Max Speed 635 RPM (Jackshaft)
Minimum Speed 360 RPM
Mechanical Efficiency 85%
Lubrication System Splash, Gravity Return
Lube Oil Capacity 1 Gallon
Lube Oil Type SAE 30
Maximum Fluid 140°F (250° Capability)
Minimum Fluid 0°F (-20° Capability)
Standard Suction Size 2.00 Inch NPT (50.8
Standard Discharge 1.25 Inch NPT (31.8
Fluid End Material Ductile Iron
Valve Type Disc Valves/Ball Valves
Hydraulic Motor Mount SAE C - 4 Bolt with 1.25”-
14T

Performance Rating

Pump Capacity @ Input Speed (RPM)

Pump Displacemen Maximum 350 RPM 500 RPM 635 RPM 750 RPM 900 RPM
t/ REV 2
Inch mm Gallon Liter PSI kg/cm gpm lpm gpm lpm gpm lpm gpm lpm gpm lpm
AW1118 2.25 57.2 0.0394 0.149 1,000 70.3 13.8 52.2 19.7 74.6 25 94.6 29.6 112 35.5 134.4
AW1122 2.75 69.9 0.0589 0.223 1,000 70.3 20.6 78 29.5 112 37.4 142 44.2 167 53 201

-46-
 Table Of Contents

1.0 Important Safety Instructions............................................................................

2.0 AW1122 Pump Features.................................................................................
3.0 Storage Instructions..........................................................................................
3.1 Short Term Storage.........................................................................................…
3.2 Short Term Storage for Severe Environments..............................................…
3.3 Long Term Storage..........................................................................................…
3.4 Returning a Stored Pump to Operation.........................................................
3.5 Precautions during Freezing Weather...........................................................
4.0 Installation Guidelines.....................................................................................
4.1 General Location..............................................................................................
4.2 Mounting Pump to Foundation and Power Source......................................
4.3 Suction Piping Recommendations.................................................................
4.4 Discharge Piping Recommendations.............................................................
5.0 How to Start a Pump.....................................................................................
6.0 Lubrication of Power End................................................................................
6.1 Recommended Lubricants..............................................................................
6.2 Oil Changes.................................................................................................…
7.0 Inspection and Preventative Maintenance
8.0 Component Parts List.........................................................................................
9.0 Service Procedures...........................................................................................
9.1 Removing the Fluid Cylinder................................................................................
9.2 Replacing Valves............................................................................................…
10.0 Servicing the Power End....................................................................................
10.1 Replacing Piston Rod Oil Seals............................................................................
10.2 Replacing Power End Bearings & Crankshaft...................................................
11.0 Fastener Torque Requirements...........................................................................
12.0 Critical Clearances.........................................................................................….
13.0 Trouble-Shooting Pumps...................................................................................…
14.0 Ordering Parts...............................................................................................…..
15.0 Additional Pump Assembly Products.................................................................
16.0 Glossary of Commonly Used Terms...................................................................
17.0 Reference Information........................................................................................
18.0 Maintenance Log...........................................................................................….

-47-
List of Figures and Charts

Table 1 Pipe Pressure Chart...........................................................................................

Table 2 Lubricant Recommendations................................................................................

Table 3 Maintenance Chart...........................................................................................
Table 4 Component Item Numbers..................................................................................
Table 5 Spline Shaft Component Item Numbers.................................................................
Table 6 Service Tool Item Numbers.................................................................................
Table 7 Torque Values for Critical Pump Fasteners...............................................................
Table 8 Clearance Chart..............................................................................................
Table 9 Replacement Rubber Item Numbers

Figure 2A Power End Components.....................................................................................

Figure 2B Power End Components.....................................................................................
Figure 3A Fluid End Components AW1122D.......................................................................
Figure 3B Fluid End Components AW1122BCD...................................................................
Figure 4 Spline Shaft Components...................................................................................
Figure 5 Using the Knock Out Tool...................................................................................
Figure 6 Additional Pump Assembly Products, Item
Figure 7 Pump Mount Bolt Pattern...................................................................................

-48-
 1.0 IMPORTANT SAFETY INSTRUCTIONS

WARNING: Many accidents occur every year through careless use of mechanical equipment. You can
avoid hazards associated with high pressure equipment by always following the safety precautions
listed below.

A. SHUT DOWN OR DISENGAGE the pump and all accessory equipment before attempting any type of service.
B. Failure to do this could cause electrical shock or injury from moving pump parts or
components under high pressure. Always adhere to “Lock Out” and “Tag Out” procedures. For
mobile equipment, be sure engines and hydraulics cannot be accidentally started.

C. BLEED OFF ALL PRESSURE to the pump and piping before performing any maintenance on the
pump. Failure to do so may spray water or chemicals at high pressure or high temperature
onto service personnel.

D. NEVER OPERATE THE PUMP WITHOUT A PRESSURE RELIEF VALVE, rupture disc, or other type of
properly sized over pressure safety device installed.

E. ALWAYS USE A PRESSURE GAUGE 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.

F. ENSURE THAT NO VALVES ARE PLACED BETWEEN THE PUMP AND PRESSURE RELIEF VALVE. If the pump is
started with a closed or restricted valve in line before the pressure relief valve, the pump may
exceed the rated or designed pressure limits and rupture causing injury to personnel.

G. USE SHIELDS OR COVERS AROUND PUMPS when pumping hot water, chemicals, or other
hazardous liquids. This precaution can prevent the exposure of service personnel to these
fluids should leakage occur.

H. ALWAYS USE GUARDS on all belt drives, couplings, and shafts. Guards can prevent personnel
from becoming entangled and injured by rotating and reciprocating parts.

I. USE EXTREME CAUTION WITH SOLVENTS used to clean or degrease equipment. Most solvents
are highly flammable and toxic. Observe all safety instructions on packaging.

J. FOLLOW NORMAL ENVIRONMENTAL GUIDELINES WHEN fluids, lubricants, or solvents are

disposed of or spilled.

K. NEVER MODIFY THE PUMP to perform beyond its rated specifications without proper
authorization in writing from AMERICAN MFG COMPANY.

-49-
 2.0 AW1122 PUMP FEATURES
The AW1122 pump includes the integral gear reduction pinion shaft. Drive shaft standard end comes
with 1-1/2” diameter shaft and 3/8” square keyway. Splined shaft option comes with 14 tooth
12/24 Diametral pitch female spline per ANSI B92.1 specifications.

Figure 1: AW1122 Pump Assembly with Pinion Shaft

-50-
3.0 Storage Instructions

Proper storage of your American Mfg Company pump will ensure that it is ready for service when
needed. Follow the guidelines below that fit the requirements of your application.

American Mfg Company pumps come from the factory without crankcase oil and are prepared
for storage periods of up to six (6) months in proper environmental conditions. Indoor storage in a
dry, temperature- controlled location is always recommended. If pumps are to be stored short term
(less than six (6) months) in a severe environment, they should be prepared using the procedures
outlined in the “Short Term Storage for Severe
Environments” section 3.2 below. If the pump is to be stored, or is inactive, for periods in excess of six
(6) months, it is necessary to prepare the pump as outlined in the “Long Term Storage” Section 3.3.
Remember that any fluid that poses an environmental hazard or is toxic must be handled and
disposed of properly.

3.1 Short Term Storage

If the pump is stored in an indoor, temperature controlled environment for less than six (6) months,
no special steps are required to prepare it for storage. As a general rule for pumps in corrosive fluid
applications, the fluid end should be drained, flushed with water or other non-corrosive cleanser and
compressed air used to blow dry whenever idle.

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 pumpage and blow dry with compressed air. Pour 1/4 to 1/2 cup
of internal rust inhibitor oil described in Table 2 (see Recommended Lubricant Chart, Section 6.0 ),
into the suction and discharge ports of fluid end, and then install pipe plugs in openings. Drain the
power end (crankcase) oil and remove the oil fill cap (or plug). Pour ½ to 1 cup of internal rust
inhibitor oil described in Table 2, into the oil fill hole and then install the filler cap. Coat all exposed,
unpainted metal surfaces (for example, Driveshaft) with preservative oil. Replace the oil fill cap, and
then cover the entire pump with a weather resistant covering such as a canvas or plastic tarp.

3.3 Long Term Storage

Long-term storage is defined as any period when the pump is in storage or idle in excess of six (6)
months. If the pump has been in service, drain any fluid from the pump fluid end, flush the fluid end
with water to clean out any of the remaining pumpage, and blow dry using compressed air. Pour
1/4 to 1/2 cup of internal rust inhibitor oil described in Table 2, into the suction and discharge
ports of fluid end, and then install pipe plugs in openings. Remove the piston cup seals as described
in Section 9.0 Service Procedures “Replacing Cup Type Pistons” of this manual, seal them in a bag to
protect against ozone, and store them in a separate location with a controlled environment where
they are protected from UV exposure. Drain the oil from the pump power end.

-51-
 Remove the rear cover to expose the drive components. Spray all internal parts with a rust
preservative that is soluble in lubricating oil while rotating the driveshaft several turns by hand to
ensure complete coverage. Replace the rear cover and add ½ to 1 cup of internal rust inhibitor
described in Table 2. Spray a rust preventative onto all exterior machined
surfaces paying attention to any unpainted areas like the crankshaft extension. Remove the oil fill cap
and store with the piston cup seals. Cap the breather opening with a plug or other suitable means in
order to keep the preservative atmosphere sealed inside the power end. Never store the pump on
the floor or ground. Always place it on a shelf
or pallet that is several inches above ground level. Cover the entire pump with a canvas or plastic
tarp. Every two months inspect the unit. Rotate the crankshaft by hand at least 4 turns during each
inspection. Drain and replace the rust inhibitor after every six (6) months of storage.

3.4 Returning a Stored Pump to Operation

Before operating a pump that has been prepared for storage, drain the preservative and lubricating
oil mixture from the power end (crankcase). If the pump has a pinion bearing, 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 outlined in this manual.

NOTE: American Mfg Company can factory prepare units for long term storage for a nominal fee if
specified at the time of order.

3.5 Precautions during Freezing Weather

Freezing weather can cause problems for equipment when pumping water-based fluids that expand
in volume when changing from a liquid to a frozen solid state. When water is left in a pump fluid end
and exposed to freezing temperatures, the expansion of the water as it freezes can rupture the fluid
cylinder of the pump and cause equipment damage. Injury may result when starting equipment that
has been damaged. Whenever the pump is stored or idle in conditions that are near or below
freezing, any water based fluids should be removed from the pump. The best way to do this is to run
the pump for a few seconds with the suction and discharge lines disconnected or open to
atmosphere. This will clear the majority of the fluid from the pumping chamber as well as the suction
and discharge manifolds. After the run, blow compressed air through the fluid end to remove all
traces of fluid. Remove cylinder head and lift up the discharge valves and remove plugs from the
bottom of the
fluid cylinder and lift up the suction valve to ensure that all fluid is drained from the pumping chamber
between the suction and discharge valves. As an alternative to the previous procedure, a
compatible antifreeze solution can be circulated through the fluid end. RV antifreeze, propylene
glycol, is recommended for this purpose. Remember that any fluid that poses an environmental
hazard or is toxic must be handled and disposed of properly.

-52-
4.0 Installation Guidelines

A proper installation is essential to optimal performance, long service life, and reduced maintenance
requirements. Take time to thoroughly plan all aspects of your installation.

4.1 General Location

It is important to position the pump on as flat and level a surface as possible to assist the splash oil
lubrication system. Park mobile equipment, such as sewer cleaner trucks or drilling machines, on as
level a surface as possible. Whenever possible the pump should be mounted in a clean, dry location
with sufficient lighting and adequate space for easy inspection and maintenance. Locate the pump
as close to the 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 AW1122 pump 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. Check
motor or engine rotation direction to ensure that the top of the pump pinion shaft rotates away from
the pump fluid end when in operation. 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 parallel to each other
with a straight edge.

CAUTION: Never operate the pump without the belt guard securely installed. For direct-coupled or
spline-driven units, ensure that the shafts are centered and parallel when the driver is mounted to
the pump. Follow the coupling manufacturer instructions for installation procedures and tolerances.
CAUTION: Never operate the pump without a shaft guard securely installed.

4.3 Suction Piping Recommendations

Poor suction piping practices are a very common source of pump problems. To ensure proper
operation it is very important to follow good design practice in the installation of the suction system
before the pump is operated.
A small amount of additional planning and investment in the piping system usually provides for better
pump performance and longer periods between service requirements. It is difficult to diagnose many
pump problems without the aid of a suction pressure gauge. For this reason, American Mfg Company
recommends that a gauge always be installed in the suction line directly before it enters the pump.

-53-
 The suction line from the fluid source to the pump should be as short and direct as possible. Use
rigid piping, non-collapsible hose or a combination of both as circumstances require in your
installation. The suction pipe size should be at least equal to or one size larger than the pump inlet.
Long piping runs, low suction heads, or indirect pipe routing may require even greater over sizing of
the suction line for proper operation of the pump. A suction and discharge 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 of the pump
to obtain sufficient pressure for the pump to operate successfully.

The suction line must be configured so there are no high spots in the line where air pockets can
collect. These pockets may make the pump difficult to prime and cause rough, erratic operation. A
drain valve or plug should be installed at the low point of the suction line to allow for draining before
freezing conditions or for maintenance.

American Mfg Company recommends that all piping be supported independently of the pump. By
supporting the piping this way, vibrations are reduced and stress on the pump is kept to a minimum.
The use of elbows, nipples, unions, or other fittings should be minimized. Make sure that all joints and
connections are airtight. Air leaks
reduce the capacity of the pump and can result in cavitation, rough operation, and/or loss of prime.
To help isolate mechanical and hydraulic vibrations, American Mfg Company recommends the use of
flexible pipe couplings or hose connections between the pump and any rigid piping.

Always ensure 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 American Mfg Company or your authorized American Mfg Company reseller.
American Mfg Company does not recommend using the pump in static lift conditions without prior
factory approval.

4.4 Discharge Piping Recommendations

1. Route the discharge piping in as short and direct a route as possible. Use the same pipe size as
the outlet of the pump. In installations where the discharge piping is in excess of 50 feet (15 meters)
it is suggested to use the next larger size pipe to minimize friction losses downstream of the pump.

CAUTION: Always use pipe or hose that is designed for your particular pressure requirements.
Inadequate pressure ratings can allow hose or pipe to fail, resulting in equipment damage and
possibly personal injury. Normal hose pressure ratings are clearly marked on the outer surface of
the hose. Working pressure ratings for steel pipe can be obtained from the manufacturer or from the
chart shown in Table 1.

2. Always use a pressure gauge in the pump discharge line. A properly functioning
gauge mounted at the pump (and before any valves) is required to accurately determine the
operating pressure of a pump and
to conduct troubleshooting.

-54-
3. Ensure that all piping is supported independently of the pump to reduce vibrations and strain on the
pump. Pulsation dampeners on the discharge are recommended to reduce pressure pulsation and
resulting vibration. The use of elbows, nipples, unions, or other fittings should be kept to an absolute
minimum. Avoid short radius
90° elbows; use two long radius 45° elbows instead. To help isolate mechanical and hydraulic vibrations,
American Mfg Company recommends the use of flexible pipe couplings or 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 discharge 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. American Mfg Company 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 be installed to allow flow to bypass the relief
valve. This allows the pump to start in an unloaded condition (no discharge pressure).

-55-
5.0 How to Start a Pump
CAUTION: Always take special precautions when starting a pump for the first time or after any
extended shutdown. Never assume that someone else has properly prepared the
pump and system for operation. Always check each component of the system prior to every
start-up. The checklist that follows is intended to be a general guide for starting a pump in a typical
installation. Every installation is different, and each will have different requirements to ensure safe and
successful operation. It is the responsibility 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, gear lube,
or a synthetic oil as described in Table 2 and that the oil has not been contaminated with water or
other contaminants.

NOTE: American Mfg Company pumps are shipped with no oil in the power frame and must be filled to
the proper level with the proper grade of oil prior to start-up.

3. If accessible, check the piston rods to ensure that they are free from abrasive particles or debris.

4. Ensure that the pressure relief valve and all accessory equipment have been installed and properly
adjusted. Verify that all joints are pressure tight.

5. Open the suction line valve to allow fluid to enter pump. Prime the fluid cylinder if necessary on the
initial start up or after the system piping has been drained. The valve covers may have to be cracked
open to assist with priming.

6. Check to ensure that power is locked out 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 acceptable for operation.

9. The pump is now ready to start. NOTICE: Whenever possible, use a bypass in the discharge line to
allow the pump to start in the unloaded condition (no discharge and pressure). Slowly close the bypass
line to bring the pump into full load conditions. Shut down immediately if the flow becomes unsteady,
pressure fluctuates, or if unusual sounds or vibrations are noted.

10. Take temperature readings of the power end and stuffing boxes. Do not exceed 170°F (77°C) on
power end.

-56-
6.0 Lubrication of Power End
6.1 Recommended Lubricants

Few factors can influence the life of a pump more than the power end lubricant (oil). Careful selection
of the right type of oil for each particular application will help ensure optimal performance from an
American Mfg Company pump.

NOTE: Lubricant temperatures should not exceed 170° F (77° C) for continuous duty or 180° F (82° C)
for intermittent duty applications. Crankcase temperatures that exceed these limits will cause the
lubricant to prematurely “break down”. The result will be poor lubrication and failure of power end
components.

6.2 Oil Changes

Oil changes must be carried out after first 100 hours of operation, and subsequently after every
4,000 hours or at least every 6 months. These intervals may be modified depending on actual
operating conditions. This model pump requires 4 quarts (3.8 liters) of oil.

1) Oil should be changed when hot to prevent build up of sludge deposits.

2) It is advisable to check oil level daily. If more than 10% of the total capacity has to be added, check

for oil leaks.

3) Do not mix oils of different types, even if produced by the same manufacturer.

4) Never mix mineral and synthetic oils.

5) To avoid the risk of scalding or burns, pay attention to oil and power end temperature during an oil

change.

6) Follow environmental guidelines when changing and disposing of lubricants.

-57-
Recommended Lubricant Chart
Oil Synthetic Lubricant*
Type of Ambient SAE ISO SSU Manufacturer SAE ISO Manufacturer
Service Temperature Grade Viscosity Viscosity Brand Grade Viscosity Brand
(cSt@40 C) Name (cSt@40 C) Name

General 0 F to 3 10 55 Texaco® Meropa 10W- 90.0@40 Shell® Rotella T

Service 100 F 0 0 0 100 30 15.0@10 Synthetic SAE
(-18 C to 38 Shell® Omala 0 5W-40
100
C) Shell® Rotella T Mobil® SCH
5W- 99.1@40
SAE 30
Exxon® XD-3 30 40 627
wt 13.9@10
Mobil® Trans 0
HD-30 NA

High 100 F to 5 22 1,165 Texaco® 5W- 90.0@40 Shell® Rotella T

Ambient 130 F (38C 0 0 Meropa 68 40 15.0@10 Synthetic SAE
Temperatu to 54 C) Shell® Omala 0 5W-40
re Service 220
Shell® Rotella T 5W- Mobil® SCH
SAE 50 217@40
Exxon® HD-3 50 40 630
29.9@10
wt
Mobil® Trans 0
HD-50 NA

Cold 0 F to -30 2 6 35 Texaco® 5W- 90.0@40 Shell® Rotella T

Ambient F 0 8 0 Meropa 68 30 15.0@10 Synthetic SAE
Temperatu (-18 C to -34 Shell® Omala 0 5W-40
re Service 68
C) Shell® Rotella T BP® Vanellus
5W- 12.0@10
SAE 20
Exxon® HD-3 20 40 E8
0
wt ULTRA 5W-
Mobil® Trans
HD-20 30
10W- 69.9@10
30 0 Mobil® SCH
10.9@10 626
NA 0
Freque 4 15 77 Texaco
nt 0 0 5 Meropa®150
Start/S
top
Operati
on
Specialty
Internal Cortec® VCI
Rust 329
Inhibit
External Texaco® Metal
Rust Protective Oil L
Preventati

Table 2: Lubricant Recommendations

-58-
7.0 I nspection and Preventative Maintenance Chart

Routine maintenance is an essential part of any successful pump installation. Properly maintained American
Mfg
Company pumps are designed to offer years of trouble-free service.

Regular maintenance and inspection will keep your pump operating at peak performance.
American Mfg Company pumps have been carefully engineered to minimize maintenance
requirements and simplify these tasks when they are required. Regular inspections allow
operators to become familiar with normal pump operation so they can recognize the signals of
potential problems and schedule maintenance. The maintenance chart in Table 3 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

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
Break In
debris.
Period
Inlet Strainer Inspect Clean if required. The amount of material in the strainer will
determine the interval of cleaning.

Complete Pump Inspect General inspection of pump and system to check for proper
operation of equip- ment.

Daily Piston Cup Sets Inspect Check the cylinder liner area of the pump for signs of leakage.
Replace piston cups if leakage becomes excessive.

Pump System Flus Required for shutdown when pumping fluids that may harden or
h corrode the pump if left inside once stopped.

Crankcase Oil Inspect Ensure that the oil is at proper level and has not been
contaminated by pump- age or condensation.

Crankcase Oil Change Drain and refill with new oil. Clean magnetic drain plugs.

12 Months
/
4,000 Stuffing Box Inspect Check the stuffing box bolts with a torque wrench to insure
Hours they are within specification.

Connecting Rod Inspect Check the connecting rod bolts with a torque wrench to insure
Bolts they are within specification. This should be done in conjunction
with oil change.

Table 3: Maintenance Chart

-59-
8.0 Component Parts List

To order service parts or see exact component configurations for your particular pump, refer to the
cross-section parts drawing in the literature kit supplied with the pump. Contact your local American
Mfg Company pump distributor or American Mfg Company if you do not have this information.
Distributor or American Mfg Company if you do not have this information.

-60-
-61-
-62-
-63-
 AW1122 Component Item Numbers

Component Component

Description Description
1 Power Frame PPFMC 5257698 1 30 Screw, Self Tapping PPFMC 1187413 2

2 Crankshaft PPFMC 1285094 1 31 Plate, Inspection PPFMC 5260567 1

3 Pinion Shaft PPFMC P511596 1 32 Pipe Plug, Power End PPFMC 1187048 2

4 Connecting Rod Assembly PPFMC 5266814 3 33 Filler Cap or Vent PPFMC A5054 1

5 Rod Bearing PPFMC P514965 3 34 Screw PPFMC 1106980 20

6 Wrist Pin PPFMC A91014 3 35 Petcock PPFMC 1187039 1

7 Crosshead Assembly PPFMC 1252939 3 37 Fluid Chamber PPFMC 1284777 1

8 Seal Holder PPFMC 3268369 3 38A Disc Valve Assembly* PPFMC 1278104 6

9 Oil Seal, Piston Rod PPFMC 1177489 9 38B Valve seat** PPFMC 1284740 6

10 Seal Retainer Nut PPFMC 1266323 3 38B Valve Ball** PPFMC 1101419 6

11 Gasket, Seal Retainer PPFMC 3268418 3 39 Cylinder PPFMC 1267586 3

12 Bearing Housing, Blind PPFMC 1248369 2 40 Piston Cup PPFMC A268N 3

13 Shim, Bearing Housing PPFMC 1252595 6 41 Piston Holder PPFMC A91663 3

14 Gasket, Bearing Housing PPFMC A91675 2 42 Hex Nut PPFMC 8309 3

15 Back Cover PPFMC P508969 1 43 Plunger Nut PPFMC A5016 3

16 Gasket, Back Cover PPFMC P508966 1 44 Piston Retainer PPFMC 1216753 3

17 Pinion Housing, Drive PPFMC 5257338 1 45 O-Ring, Rod Seal PPFMC 1101176 3

18 Pinion Housing, Blind PPFMC P508916 1 46 Gasket, Fluid Cylinder PPFMC 1279676 6

19 Oil Seal, Rotating PPFMC 5257339 1 47 Stud, Fluid Cylinder PPFMC A91672 2

20 Gasket, Pinion PPFMC A91674 2 48 Hex Nut PPFMC 1121513 8

21 Screw Set PPFMC 1182004 3 49 Valve Cover PPFMC 1285113 3

22 Name Plate* PPAM A000441000 1 50 Gasket, Valve Cover PPFMC 1279675 3

22 Name Plate** PPFMC 5277981 1 51 Clamp, Valve Cover PPFMC A80391 3

23 Bearing Cone, Crank PPFMC 1177473 2 52 Stud, Valve Cover PPFMC A5076 6

24 Bearing Cup, Crank PPFMC 1177474 2 53 Hex Nut, Valve Cover PPFMC 1121511 6

25 Bearing, Pinion PPFMC P511746 2 54 Cylinder Cover PPFMC 1285112 3

26 Key PPFMC 1104349 1 55 Gasket, Cylinder Cover PPFMC 1279674 3

27 Cap screw, Pinion Bearing PPFMC 1100054 12 56 Suction Plug PPFMC 1105121 3

28 Cap Screw, Inspection Plate PPFMC 1100804 2 57 Clamp, Cylinder PPFMC A80392 3

29 O-Ring, Bearing PPFMC 3226710 2 58 Stud, Cylinder Cover PPFMC 1279602 6

* AW1122D
** AW1122BCD
Table 4: Component Item Numbers

-64-
 Component
Item # Description Part # Qty
1 Power Frame PPFMC 3269402 1

3 Pinion Shaft Splined PPFMC 3269385 1

17 Motor Mounting Plate PPFMC 3269351 1

19 Oil Seal PPFMC 3269370 1

20 Gasket PPFMC 3269398 2

25 Bearing PPFMC 3269369 2

27 Screw PPFMC 3268086 4

Table 5: Spline Shaft Component Item Numbers

-65-
9.0 Service Procedures

American Mfg Company pumps are designed to simplify all required maintenance. The following
sections illustrate step-by-step instructions for performing most common service procedures of a pump.
Read each section before starting service work on the pump. Refer to Figures 2 and 3 for the location 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.
Service Tip -- Press the piston assembly into the NOTE: The following tools are available and may be
liner until the sealing lip has just entered the Purchased at American Mfg Company’s worldwide
front of the liner. Use a small amount of glycerin network of distributors.
on the ID of the liner to help lubricate the piston
during installation. After the liner
Component Description Part #
has been installed in the pump power frame,
drive the piston assembly fully to its stop using Tool, To Press Seals On Seal Holder PPAM A000384000

the American Mfg Company piston tool (PPFMC Tool, To Tighten Packing Nut PPAM A000385000
A5049) and a rubber mallet. Tool, To Press In Seal On Pinion Caps PPAM A000386000
Tool, Bearing Press For Pinion PPAM A000387000

1. It is recommended that a sufficient quantity Tool, For Housing Cup Press PPAM A000388000
of clean water be pumped through the fluid Tool, Hand Crank Pinion PPAM A000392000
end before starting any service procedures Tool, Stud Nut PPAM A000393000
that involve fluid end components. This will Tool, Disc Valve Seat Driver PPAM A000399000
remove a significant portion of contaminants Tool, Ball Seat Driver PPAM A000233000
left in the fluid cylinder by the normal Tool, Piston Nut Remover PPFMC A5049
pumpage and improve the ability to work Tool, Ball Magnet PPAM A000239000
with parts or see potential problems.

Table 6: Service Tool Item Numbers

2. Bleed off all pressure inside pump fluid end
before starting any service work. Shut the
valve off on the inlet piping, if provided, to
prevent flow of liquid from the source into the
pump during service.

CAUTION: Check to ensure that the power is

locked out and tagged out (motor or engine
cannot be started).

-66--