Section 6

Triplex Pacemaker Pumps

Troubleshooting Pacemaker Pumps

OSSM/O I SEC 6 1
 Specifications for Model 35-8-5/RAM/ACC with 8V71 Engines

MINIMUM NORMAL MAXIMUM

Pacemaker Oil Pressure 40 PSI 40 - 120 PSI 125 PSI
Pacemaker Oil Temp. (Std) 70 F 155 F 160 F
(Synthetic Oil) 60 F 155 F 200 F

OSSM/O I SEC 6 2
 Pump Cover Connecting &
Crosshead Assembly

Crank Shaft

Counter Shaft
Oil Pan

Cross Section of the Pacemaker Pump

The Pacemaker Pump consist of two sides.

The power end side, which consist of a crankshaft, connecting rods,

crosshead assembly, counter shaft, oil pan, pump cover and pressurized oil
system.

OSSM/O I SEC 6 3
 Discharge Valve Discharge Valve Cap

Ram Wash Discharge Manifold

Oilers

Plunger

Plunger Rod

Suction Manifold

Cross Section of the Pacemaker Pump

The fluid end side consist of the ram wash, oilers, plunger, plunger rod,
suction valve cap, suction manifold, discharge manifold, discharge valve
cap, discharge valve, discharge seat and suction valve.

OSSM/O I SEC 6 4
 Pacemaker Power End
The power end of the pump is designed to accept either clockwise or
counterclockwise rotation by an interchange of existing gears. The power
end main components are: crankshaft, connecting rod and crosshead and a
pressurized oil system.

The exterior should be cleaned and inspected for oil leaks, cracks,
loose bolts and damaged oil lines every hitch when in use. Check
for proper lubrication to bearings and cross heads every hitch.

The interior should be inspected every hitch.

Remove the power end cover and check for evidence of water
contamination or emulsification if there is not a sight glass installed.

A good practice would be to check the power end after the completion of
each on site operation.

OSSM/O I SEC 6 5
 Pump Oil Level Check
Check the oil level before operation the pump. The power end requires 25
gallons of Hypoid All Purpose Oil or Multi-service Oil 80W-90.

The oil should be 1/2 below the bottom of the cover lip or about
center of the sight glass.

OSSM/O I SEC 6 6
 Oiler Lubrication System
The lubrication tanks are usually located under the 20 1/2 bbl side of the
RAM.

The Oiler Lubrication System usually consist of three (3) oiler tanks. The
A/L Pacemaker(B) Pump Packing, the A/R Pacemaker(C) Pump Packing .
The oiler tanks are pre-set at 30 psi by a regulator under the control panel,
but according to the Pacemaker manual, can be regulated between 25-50
psi. The check valves for the packing lube will open at 11-15 psi unless
using a Martin Decker type check valve, which requires 31 psi to open.

There is a tank for the Recirculation Pump Oiler. The Recirculation pump
oiler should not be set above 7 psi when using Oil seals.

There is also a tank used for the defoamer system and the pressure setting
for this tank is normally about 30 psi.

OSSM/O I SEC 6 7
 Plunger Lubrication System
The plunger lubrication systems oil reservoir will hold 10 gallons or more
of rock-bit oil.

The level should be within 1/4 of the top of the reservoir.

During constant or prolonged operation check the oil every 4 hours and
add as needed

A regulator valve is located just as the oiler line ties into the oiler
manifold. This valve can be used to regulate the rate of oil to the packing
glands.

There should be breather vents on all Pacemaker pumps to allow heat

from the case to escape and pull in cool air. They can be located on the top
of the pump mounted in the fill cap or mounted on the side of the housing.

The Pacemaker pump breathers should be inspected and cleaned

every 30 days.

OSSM/O I SEC 6 8
 PRESSURE GAUGE
FILTER

HEAT EXCHANGER

PRESSURE
RELIEF
VALVE SET
@200 PSI
PRESSURE
RELIEF
VALVE SET
@125 PSI

PACEMAKER
LUBRICATION
PUMP
PUMP

CHECK VALVE

OIL PAN

Pacemaker Lubrication Flow Chart

The pacemaker lubrication system starts from the oil pan and is sucked by
a commercial shearing pump through a 2 check valve.
It enters the pump and is discharge downstream to the heat exchanger
and then the pacemaker filters.
If the line or filters are plugged the pop-off in the line will return the fluid
back to the suction side of the pump.
The fluid goes through the pacemaker pump manifold and returns to the
oil pan.

OSSM/O I SEC 6 9
 COMMERCIAL SHEARING
LUBRICATION PUMP

PUMP POP-OFF

The pacemaker pump is lubricated by a Commercial Shearing pump

mounted on back of the drive engine. This is a gear driven pump, thus it
has to have a pop-off installed downstream of the pump to insure that the
line will not burst under pressure if the line is plugged at the pump.
There is a pop-off installed down stream of the lubrication pump and
should be set at 200 psi.

OSSM/O I SEC 6 10
 During continuous operations the oil should be changed every 30
days and every 180 days or 400 hours during intermittent
operations. It should be changed any time it becomes contaminated.

A pressure relief valve located either on the front or rear of the pacemaker
should be set at 125 psi. It can be adjusted if necessary.

When the maximum pressure is exceeded the oil is bypassed to the oil
pan. The minimum allowable pressure is 40 psi and any prolonged
operation at a lower oil pressure can result in damage to bearings and
gears.

OSSM/O I SEC 6 11
 The power end may be assembled with a fluid end using a wide range of
plungers.
The maximum flow rate and pumping pressure desired would determine
which plunger sizes are used.
Maximum working pressure for a 3.5 plunger is 15,000 psi
Maximum working pressure for a 4.0 plunger is 12,500 psi.
Maximum working pressure for a 4.5 plunger is 10,000 psi.
Maximum working pressure for a 5.0 plunger is 8,500 psi.
Maximum working pressure for a 5.5 plunger is 7,000 psi.
Maximum working pressure for a 6.0 plunger is 6000 psi.
The pump is designed so that inspections and replacement of parts is
relatively easy.
The suction and discharge valves and plungers are accessible through
threaded caps in the fluid end.
All of the pump parts can be replaced without special fittings.

OSSM/O I SEC 6 12
 Suction Valve Removal and Installation
Should a valve begin to miss or not pump properly it should be removed
and repaired or replaced.
Shut engine down and utilize the Locked-out/Tagged-out procedure.
Check to see all high pressure valves are in open position.
Open suction manifold valves to drain fluid from suction end.

OSSM/O I SEC 6 13
 To reach the valve the first step is to remove the valve cap. This is done
by using a bar.
Remove suction caps from fluid end using a valve bar or 5 pinch bar. No
hammer on caps. (Use hammer on the valve bar or pinch bar).
Put caps down in order of removal. (In front of respective chamber)
Using the proper extracting tool, pull suction valves from fluid end.
Once the suction valve assembly has been removed it should be inspected
for breaks or cracks.
Check valves inserts by depressing spring and visually checking for pits,
grooves or washes.
Check all other hardware on valves.
Replace all damaged hardware necessary.

Suggestion: The ideal program to follow is to change out all three

suction valves at the same time and repair the ones removed from
the pump at a later time.

OSSM/O I SEC 6 14
 Minimum Stand-off
Clearance
3/64

A washed condition will appear as a very smooth groove in the lip of the
valve or seat. This is usually caused by some foreign particle holding the
valve partially open.
Make sure the suction valve has the minimum standoff of 3/64 inch.
To determine the standoff condition, place the valve in the insert and
measure the amount of the insert lip that appears above the back edge of
the valve. If the minimum standoff condition is not present, the insert
should be replaced.

OSSM/O I SEC 6 15
 Valve should not move
more
than .0312 inch

While the suction valve is out check the valve guide for wear by
disassembling the valve and with the spring removed, attempt to move the
valve from side to side.

If the valve moves more than .0312 inch the valve guide insert should
be replaced.

Check the valve spring for cracks and see if it meets the specifications in
the service manual.

OSSM/O I SEC 6 16
 Check for cracks on
valve spring

Check the valve spring for cracks and see if it meets the specifications in
the service manual.
There are two types of springs that can be used.
The spring used for Cementing will be P/N 112856 and will have a 60
lb/in spring compression rate.
The spring used for Fracturing and Acidizing will be P/N 115823 and will
have a 120 lb/in spring compression rate.

OSSM/O I SEC 6 17
 Suction Valve Assembly Steps
Step 1 Step 2

Step 3 Step 4

Step 5 Step 6 Step 7 Step 8

After your are certain that every thing is as it should be, the valve needs
to be reassembled. Be sure the valve and the seating are clean then coat
the out side of the o-ring, backup ring, and suction valve guide with grease
or heavy oil. The torque on the hex nut should be 50 foot pounds against
the valve spring retainer.
Make sure the top of the stem to the lock nut is the same on all valves.
The valve opening should be no less than 1/2 inch. If the clearance is
smaller, it may cause cavitation of heavier viscosity fluids.

CLEARANCE
MOST USED IS Minimum of 1/2
5/8 INCH WHICH
Clearance
IS USED IN
CEMENTING AND between the
ACIDIZING guide insert and
the spring
retainer

Install the valve assembly into the fluid end as far as possible.

OSSM/O I SEC 6 18
 Ensure that the o-ring on the suction cap is clean and coated with grease
or heavy oil. Install the cap in the fluid end.

Tighten with valve bar or pinch bar. (Never hammer). Hammer on valve
bar or pinch bar.

Remove Lock-out/Tagged-out and run unit.

Check for leaks.

OSSM/O I SEC 6 19
 PACEMAKER SUCTION VALVE

1 118499 NUT, HEX LOCK 1/2-20 NF STEEL 8

1 A 115823 SUCTION VALVE SPRING RETAINER 7

A 112512 SPRING, COMPRESSION (120 LB/INCH SPRING RATE) 6

-2
1 A 112856 SPRING, COMPRESSION (60 LB/INCH SPRING RATE) 5
-1
1 C 115376 SUCTION VALVE GUIDE INSERT 4

1 B 120145 SUCTION VALVE GUIDE 3

1 40110 SEAT, SUCTION VALVE WITH O-RING AND BACK UP RING 2

1 40111 VALVE, SUCTION WITH INSERT 1

-1 ASSEMBLY is for Cementing Type of Operation
-2 ASSEMBLY is for Fracturing and Acidizing Type
of Operation
NOTES:

1 TORQUE TO 50 FOOT LBS

.
2. PERMANTENTLY MARK BJ P/N 36585BJ WITH SUFFIX -1
OR -2 AS SHOWN
3. TOOL REQUIRED FOR REMOVAL FROM FLUID END-
SUCTRIN VALVE PULLER BJ P/N 123496-2

DWG. PART OR NOMENCLATURE ITEM

MATERIAL/ SPECIFICATION
OR DESCRIPTION NO.
SIZE IDENTIFYING NO.

2 3

4 6 -2 Assy
1
5 -1 Assy

7
Ref O-ring AS568-352 NTRL 90
DURO BJ P/N XAS-352-02
8

Minimum 1/2 Valve

Ref Suction Valve Insert BJ Opening
P/N 36583BJ Ref Back-up Ring, Teflon, BJ P/N
120531-30

FULL SECTION

OSSM/O I SEC 6 20
 Discharge Valve Removal and Installation
It is sometimes necessary to work on the discharge valves and seats.
Shut down engine and use the Lock-out/Tagged-out procedure.
Check to make sure all high pressure valves are in the open position.
Remove discharge caps using valves bar or 5 pinch bar. (No hammering
on caps.)
Put caps down in order of removal.
Put all hardware in front of corresponding chamber.
Pull discharge springs from fluid end and check.
Remove discharge valves from fluid end and check valve inserts, valve
bodies and valve seats in the fluid end.

OSSM/O I SEC 6 21
 Check o-rings on discharge cap and grease.
Replace caps in order of removal and tighten with valve bar (never
hammer) hammer on valve bar.
Test pumps.

OSSM/O I SEC 6 22
 Minimum Stand-off
Clearance
3/64

Insert Stand-Off
A washed condition will appear as a very smooth groove in the lip of the
valve or seat. This is usually caused by some foreign particle holding the
valve partially open.
Make sure the discharge valve has the minimum standoff of 3/64
inch. To determine the standoff condition, place the valve in the insert and
measure the amount of the insert lip that appears above the back edge of
the valve. If the minimum standoff condition is not present, the insert
should be replaced.
The compression spring to be used for Cementing Operations is P/N
112818 and is a 75 lb/in spring rate.
The compression spring to be used for Fracturing and Acidizing is P/N
120004 and is a 125 lb/in spring rate.
The traveling distance of the discharge valve from the top of the valve to
the bottom of the discharge cap should be 3/4 inch.

OSSM/O I SEC 6 23
 PACEMAKER DISCHARGE
VALVE ASSEMBLY

Step 1 Step 2 Step 3

Step 1 - Replace the insert if it has pits or is loose on the discharge valve.
Step 2 - Insert the discharge valve complete into the discharge seat.
Step 3 - Insert the discharge valve spring onto the discharge valve.
Step 4 - Replace discharge cap after checking the o-ring and back-up
teflon ring.

OSSM/O I SEC 6 24
 PACEMAKER DISCHARGE VALVE

1 A 120004 2 SPRING, COMPRESSION (125 LB/ INCH SPRING RATE) 4

1 A 112818 1 SPRING, COMPRESSION (75 LB/ INCH SPRING RATE 3

1 1 40497 DISCHARGE VALVE WITH INSERT 2

1 1 40496 DISCHARGE VALVE SEAT WITH 0-RING 1

DWG. PART OR NOMENCLATURE ITEM
-1 -2 MATERIAL/ SPECIFICATION
SIZE NO.
IDENTIFYING NO. OR DESCRIPTION

NOTE:
1. PERMANENTLY MARK BJ P/N 36627 WITH
SUFFIX -1 OR -2 AS SHOWN BELOW:

-2 FRACTURING & ACIDIZING 125 LBS. SPRING

-1 CEMENTING 75 LBS. SPRING

Ref Pump Discharge Cover

VALVE ASSY,
DISCHARGE
PACEMAKER PUMP

1/1 C 36627BJ A 4 -2 Assy

3 -1 Assy

(3/4)
Valve
Opening 2

Ref Discharge
Valve Insert BJ
P/N 36629BJ

Ref. O-Ring
AS568-240 NTRL
70 DURO BJ P/N
XAS-240-01

FULL SECTION 1

OSSM/O I SEC 6 25
 DISCHARGE
VALVE SEAT
REMOVAL

Remove discharge cap from fluid end by using valve bar or pinch bar to
loosen caps
Remove discharge spring and discharge valve from the fluid end.
Remove suction valve cap and suction valve from fluid end.
Move plunger to extreme rear position.
Install valve seat puller through suction cylinder and place puller mandrel
against discharge valve seat.
Tighten puller nut.
Replace suction valve assembly and suction valve cap.
Fill fluid end discharge cylinder with water.
Replace discharge cap and bottom out threads, then back off cap 1/4 turn.
Rotate pump slowly to release discharge valve seat.
Remove discharge cap and remove discharge valve seat and puller from
fluid end.
Replace discharge cap and bottom out threads, then back off cap 1/4 turn.
Rotate pump slowly to release discharge valve seat.

OSSM/O I SEC 6 26
 REMOVE THE OLD SEAT FROM REPLACE WITH NEW SEAT
PUMP AND O-RING

Remove discharge cap and remove discharge valve seat and puller from
fluid end.
Remove remaining water from the fluid end and discharge cylinder and
dry cylinder with clean shop towel.
Install discharge valve seat with new o-ring and discharge valve assembly
into fluid end.
Ensure the discharge valve cap and o-ring are clean and free of dirt and
cement, then coat o-ring and threads with grease or heavy oil.
Install discharge cap into fluid end and bottom out threads.
Load fluid end with water and pressure up on pumps to seat discharge
valve seats. (recommended to seat with 5000 psi)

Note: Some discharge seats will take from 5000 to 10000 psi to seat.

OSSM/O I SEC 6 27
 HOW TO PACK A PACEMAKER PUMP
Tools Needed:Plunger packing Driver (P/N 114536), Plunger Packing and
Removal Tool (P/N 120402), Tee Wrench (P/N 112830), Gland/Spanner
Wrench (P/N 120329), dash numbers will be used to specify 3.5, 4,4.5
and 5 plungers.

Another pump component that will need occasional attention is the

plunger packing.
Begin by removing the valve cap and suction valve assembly.
Rotate the pump until the plunger is in the extreme forward position.
Open the ram wash and packing lubricant cover.
Loosen the nut and remove the oil line from the packing gland assembly.
Using the gland/spanner wrench, loosen the packing gland assembly.

OSSM/O I SEC 6 28
 Insert the Tee handle wrench into the plunger and rotate it counter
clockwise to loosen the plunger.
The plunger can now he removed from the fluid end.
Insert the Tee handle into the plunger cap and rotate the wrench counter
clockwise to loosen the plunger rod.
Remove the plunger cap, plunger rod and o-ring from the plunger and
fluid end.

OSSM/O I SEC 6 29
 Rotate the pump until the cross head is in the extreme back/rear position
then insert the plunger puller/driver into the plunger.
Install the puller/driver stud end into the plunger then using the sliding
hammer on the puller/driver, hammer the plunger loose from the packing
gland assembly and remove the plunger from the fluid end.

PULLER/DRIVER

Remove the packing gland assembly from the fluid end.

OSSM/O I SEC 6 30
 Fluid End Seal Power End

1 2

PACKING GLAND MAINTENANCE

Inspect the cross head seal and replace the crosshead seal, then carefully
remove the packing gland loading and unloading tool (if spring loaded
packing is being used).
Disassemble the packing gland.
1

Set up new rod seal (purple ring), packing, header ring.

Clean back ring (oiler ring), spacer ring, and seal ring (make
2 sure to change o-rings before assembling)

Clean gland box and apply light coat of oil. Check that oiler
ports are free of cement or debris. Lightly oil threads on the
3 gland box for assembly.

OSSM/O I SEC 6 31
 STEP 1
STEP 4 STEP 7

STEP 2 STEP 5 STEP 8

STEP 9

STEP 3 STEP 6

Step 1-Lightly oil the inside of the gland box and install the Parker Rod
Seal with the o-ring facing up.
Step 2-Lightly oil the back ring (oiler ring) and carefully install. Use a
hammer handle to install if it becomes difficult.
Step 3-Lightly oil and install the first of two Utex pressure rings. The
chevron should be facing down() and the groove facing up.
Step 4-Lightly oil and install the second of two Utex pressure rings. the
chevron should be facing down() and the groove facing up.
Step 5-Lightly oil and install the header ring.
Step 6-Lightly oil and install the steel spacer ring.
Step 7-Lightly oil and install the seal ring (spool ring). Be sure to replace
the o-rings before installing.
Step 8-Install the packing gland loading and unloading tool in the packing
gland and tighten the tool until it is snug.
Step 9-Install the packing gland into the fluid end and tighten with the
packing gland spanner wrench.
Step 10-Remove the packing gland loading and removal tool from the
packing gland assembly and using a spanner wrench, tighten the packing
gland assembly.

OSSM/O I SEC 6 32
 National Oil Seal

Towards
Power
End

Every time the plunger is pulled the National Oil Seal should be changed.
There are two ways to do this:
1-remove the crosshead seal cover and remove the National Seal
and replace with a new one. If removing the crosshead seal cover, a
new seal cover gasket may have to be installed.
2-while the plunger is out, place the National Oil Seal in the
crosshead seal cover and tap evenly in place with a small hammer.
When installing the oil seal, it is suggested to coat with Permatex No. 2 or
equivalent (BJ P/N 118409)

OSSM/O I SEC 6 33
 Remove the o-ring from the cap end of the plunger, coat the plunger with
oil and insert it into the packing gland assembly through the suction valve
opening.
Insert the driver end of the plunger puller/driver into the plunger and
using the sliding hammer, drive the plunger through the packing gland
assembly until it is seated against the cross head.
Install the o-ring into the cap end of the plunger and install the plunger
cap, with the assembled plunger rod, into the plunger.
Tighten the plunger cap against the plunger until it is snug.
Attach a cheater pipe to the Tee handle wrench and insert the wrench into
the plunger cap.
Rotate the pump and tighten the plunger cap during the pressure stroke
of the plunger.
Tighten the plunger cap to between 320 to 350 foot pounds of torque.

OSSM/O I SEC 6 34
 1

5
6

Tools used in Assembly and Disassembly of Pacemaker

Pump

1. Suction Valve Removing Tool (old)

2. Suction Valve Removing Tool (new)
3. Tee Wrench for Plungers
4. Gland Wrench
5. Plunger Installation Tool
6. Plunger Installation and Removal Tool

OSSM/O I SEC 6 35
 Not
Approved
by
Engineering
yet

New Plunger Installation Tool for Hollow Plungers

OSSM/O I SEC 6 36
 Before connecting oil lines, assemble check valve on line and turn oilers
on to make sure oil is coming out. The oilers should use Rock Bit oil and
the pressure on the oiler tank should be between 25-50 psi. All new 35-8-5
units have the oiler preset at 30 psi by a regulator located inside the
control console on the auto right side.
It takes 31 psi to open the M/D F-350-1 check valves and 11-15 to
open M/D F-350-6 check valves. Make sure of the type of check valve being
used.
Connect the oil line to the packing gland assembly.
Replace the suction valve assembly and suction cap.

OSSM/O I SEC 6 37
OSSM/O I SEC 6 38
OSSM/O I SEC 6 39
 Problem:
Low or fluctuating
lube oil pressure

Possible Cause:
1) Bad gauge check with a gauge known to be good
2) Low engine RPM check at engine speed of 1700
rpm minimum
3) Low oil level check and correct
4) Hot oil check with oil at normal temperature
5) Bad or incorrectly adjusted relief valve check
adjustment, remove and install relief valve known to be
good
6) Bad lube oil pump replace and re-check (ref. lube
oil schematic)
7) Pacemaker pump clearances to great check
crankshaft and bearings-repair as required

OSSM/O I SEC 6 40
 Problem:
Lube oil temperature high

Possible Cause:
1) High engine coolant temperature= see Section One
Troubleshooting, Part A, Step 7, Page 8

OSSM/O I SEC 6 41
 Problem:
Unequal flow of plunger lube
oil to plungers

Possible Cause:
1) Air locked bleed plunger lube valve
2) Plunger lube valve plugged disassemble valve
and clean
3) Worn packing inspect and replace as required

OSSM/O I SEC 6 42
 Problem:
Ratemeter shows lower rate
than displacement tank

Possible Cause:
1) Ratemeter calibrated incorrectly calibrate per
instrumentation procedure

OSSM/O I SEC 6 43
 Problem:
Ratemeter shows higher rate
than displacement tank

Possible Cause:
1) Ratemeter calibrated incorrectly calibrate per
instrumentation procedure
2) Pacemaker suction or discharge valve leaking
repair and re-check
3) Suction cover sucking air repair and re-check

OSSM/O I SEC 6 44
 Problem:
Pacemaker pump
Hammering or excessive
vibration:

Possible Cause:
1) Pacemaker suction or discharge valve leaking
repair and re-check
2) Suction cover sucking air repair and re-check

OSSM/O I SEC 6 45
 Problem:
Pump will not pump fluid

Possible Cause:
1) Overpressure shutdown tripped reset
overpressure shutdown
2) Suction valve closed open valves
3) Clearance on suction valves to closed open
suction valve clearance at least 1/2-inch

OSSM/O I SEC 6 46