1-08-E - R0 Maintenance - 1000

Volume I / 8 Maintenance
MAINTENANCE
8.1 General ...............................................................................3

8.2 Safety ..................................................................................4
8.3 Maintenance Intervals .........................................................7
8.4 Welding ...............................................................................7
8.5 Notes to Maintenance Manual ............................................8
8.6 Operations before / during / after Maintenance...................8
8.7 Hydraulic Hoses and Hose Lines ......................................11
8.8 Lubricants / Oils ................................................................12
8.9 Torque and Tensioning Setting Values .............................14
8.9.1 Screw Tightening Torque (Nm) .........................................14
8.9.2 Pressure Values for Hydraulic Tools.................................14
8.10 Maintenance......................................................................15
8.10.1 Removal and Installation of Valve Closures......................16
8.10.1.1 Removal ............................................................................16
8.10.1.2 Installation .........................................................................17
8.10.2 Removal and Installation of Valve Seats...........................18
8.10.2.1 Removal ............................................................................18
8.10.2.2 Installation .........................................................................19
8.10.3 Turning of Mud Pump by Hand .........................................20
8.10.4 Removal and Installation of Pistons & Piston Rods ..........22
8.10.4.1 Removal ............................................................................22
8.10.4.2 Installation .........................................................................23
8.10.5 Removal and Installation of Liners ....................................24
8.10.5.1 Removal ............................................................................24
8.10.5.2 Installation .........................................................................25
8.10.6 Removal and Installation of Pressure Connection ............26
8.10.6.1 Removal ............................................................................26
8.10.6.2 Installation .........................................................................26
8.10.7 Drive Mode........................................................................27
8.10.7.1 Belt Drive...........................................................................27
© WIRTH Maschinen- und Bohrgeräte-Fabrik GmbH - Änderungen vorbehalten / Subject to modifications
8.10.7.2 Chain Drive .......................................................................27

8.11 Repair of Mud Pump .........................................................28
8.12 Maintenance Chart with Execution Remark ......................29
8.13 Trouble Shooting Chart .....................................................35
Annex:
Survey on Filling Quantities / Maintenance Materials ......................1/1

Maintenance Scheme.......................................................................1/3
Mud Pump Components (Manufacturer) ..........................................1/1
(Optionally for Belt Drive)

Power Belts of Belt Drive....................................................................... I 0002490
Pumps\TPK\7_1-4-8_1-2-1000\Description\1-08-E_R0 Maintenance-1000.doc 21.04.06 - Rev. 0 1 / 39

Maintenance Volume I / 8
Rev. Page Description Made by Remark
2 / 39 21.04.06 - Rev. 0 Pumps\TPK\7_1-4-8_1-2-1000\Description\1-08-E_R0 Maintenance-1000.doc

8.1 General
The irreproachable function and operational safety of the pump depends on the thorough care and
maintenance.
This section covers, beneath the regular maintenance activities, the replacement of items that may
require renewal as part of a regular maintenance program or items that need replacing as part of the
operational requirement.
Never try to remedy defects or to carry out any repairs for which you do not dispose of the required
experience and special tools.
We do not assume any liability for damage caused by the non-observance of maintenance
instructions.
DANGER : PERSONAL PROTECTIVE EQUIPMENT (PPE)
Before starting setting, maintenance and repair work the personal protective equipment
required by the safety regulations must have been made available to the personnel and the
personnel should use them, such as gloves, goggles, helmet, non-skid safety shoes, etc. ….
ATTENTION WORKING IN INSUFFICIENTLY ILLUMINATED AREAS

If the operator at the pump has to work in dark areas, he should use a portable lamp with
magnet.
THE LAMP TO COMPLY WITH THE REGULATIONS !
DANGER:
Any work relating to setting, maintenance and repair may only be carried out after the pump
has been set off operation and cut-out.

8.2 Safety
Before any maintenance work is carried out, the following safety measures should be observed:
• There may only be charged those persons

who have reached the age of 18 years
who are physically and mentally capable to this work
who have been instructed in operations on the pump and have proved their capability
to do so towards the user, and
from whom it can be expected that they reliably fulfill the tasks entrusted to them.
• The operator’s permit to work system must be adhered to.
• The mud pump must be stopped and isolated from the electricity supply.
• The lubricating oil and the exterior surfaces of the mud pump can reach temperatures
approaching 70o C during operation. Maintenance personnel must be aware of this, and a
sufficient cooling off period should be allowed prior to maintenance of the hot parts of the
pump.
• The fluid end and other pressurized lines must be depressurized.
• The suction and discharge dampener must be depressurized.
• The work area must be adequately lighted so that good all round vision is assured.
• Audible warning signals provided by the operator in the mud pump area shall be of
sufficient volume to be heard by the attending personnel when all pumps are working
anywhere within their operating spectrum.
• Visual warning signals provided by the operator in the mud pump area shall be located
such that they are clearly visible to attending personnel.
• Safe access must be provided to all items of equipment that cannot be reached from floor
level.
• In supplement to the Maintenance Manual consider and instruct any general, legal and © WIRTH Maschinen- und Bohrgeräte-Fabrik GmbH - Änderungen vorbehalten / Subject to modifications
otherwise binding regulations to accident prevention and environmental protection!
• Complete the Maintenance Manual by instructions including supervision and registration

obligations with regard to the consideration of company internal particularities, e.g.
organization of work, operation sequences, charged personnel.
• Before starting any work, the personnel charged with the operations on the pump must
have read and understood the Maintenance Manual, here, especially the chapter safety
regulations. During working proper, it will be too late. This especially applies to staff that
only occasionally works at the pump, e.g. for rigging-up, maintenance, etc. …
• Verify the safety and risk conscious working of the personnel on the basis of the
Maintenance Manual, at least occasionally!

• The personnel must not wear long open hair, loose-fit clothes or jewelry including rings.
There is the risk of injuries, e. g. by getting stuck or seized.
• Wear personal protective equipment to the required extent and as demanded by

prescriptions!
• Keep all safety and caution notes on the pump in mind!
• Keep all safety and caution notes at/on the pump fully in legible condition!
• In case of safety-relevant modifications of the pump or its operational attitude, stop pump
immediately and inform competent service/person !
• Never make any changes on, attachments to and restructuring of the pump that could
affect safety without supplier’s prior approval! This applies to both the installation and
setting of safety units and valves and to welding of supporting elements.
• Spare parts should always meet the technical requirements defined by the manufacturer.
This is always ensured using WIRTH original spare parts.
• Inspect hydraulic hose lines at regular adequate intervals and exchange them, if required
so (also see page 11).
• Adhere to prescribed terms or those indicated in the Maintenance Manual for repeating
checks/inspections!
• To carry out maintenance measures a workshop equipment as required by the level of

work is indispensable.
• Make place and use of fire extinguishers public!
• Consider fire alarm and fire fighting possibilities!
• Charge trained and instructed personnel, only, for operation, rigging-up, maintenance and
repair work!
• Make sure that only authorized personnel operates and works at the pump!
• Staff to be trained, instructed or informed or personnel acting within the scope of a

general training measure may only become active at the pump under the permanent
supervision of an experienced person!
• Working on the electric equipment of the pump may only be done by a qualified electrician
or instructed persons under direction and supervision of a qualified electrician in
accordance with the electro-technical rules!
• The maintenance crane provided with each pump must be load-tested and certified at
least once per year, or more frequently depending on the operator’s safety procedures.
• The maintenance crane provided with each pump must not be loaded beyond the safe
working load (except during load testing).
• All auxiliary lifting equipment (slings, shackles, chains, etc. ...) must have been tested and
have a valid test certification. All auxiliary lifting equipment used with the maintenance
crane, must be certified for its respective lifting capacity.

• The pressure gauge on the hydraulic hand pump must be calibrated at regular intervals to
ensure accurate pressure readings.
ATTENTION
To comply with EC Regulations, each mud pump shall be fitted with emergency stop
breakers located on each side of the pump. All pump electrical drives shall be provided with
a load circuit breaker (key switch) for maintenance purposes. Emergency stop breakers and
key switches are not supplied as part of the pump. They are not WIRTH scope of supply.

8.3 Maintenance Intervals

After certain periods of time / intervals, maintenance work has to be carried out on the pump. This
work is determined either by the operating hours (see hourmeter) or by calendar periods (daily,
weekly, etc. …). If maintenance work is done in accordance with calendar periods, those must
approximately correspond to the number of operation hours.
NOTE
Extreme conditions, e.g. dust production, may require more frequent maintenance.
If, due to reduced use of the pump, these intervals exceed half a year, all outside parts to be greased
should be greased, at least, every six months.
If the pump is off operation for more than 3 months, all blank parts should be preserved against
weather influences.
The gearings are configured as oil-bath lubricated gearings that do not require any specific
maintenance, except of the regular oil change.
Pressure set values in the hydraulic system should be checked by qualified personnel at regular
intervals.
8.4 Welding
If welding work is to be done on the pump, following precaution measures must be adhered to:
• Welding work on statically important components may only be done after written approval by
WIRTH.
• Welding work may only be done by qualified personnel.
• The earthing terminal of the welding machine is to be connected directly to the part to be welded.
The welding current must in no case be conducted detouring via electronic components.
ATTENTION
Do not connect the earthing terminal of the welding machine to the assemblies (motor, gear-
box, etc.). The welding current can provoke spark discharge at bearing points inside the
assemblies. The texture alterations caused hereby at the contact points of bearings can
distinctly be evidenced as new hardening zones. This previous deterioration causes the
premature failure of the gear-box. Do not touch housings of electronic components (e.g.
control instruments) and electric lines with the welding electrode or earthing terminal of the
welding machine.
Welding must not be carried out:

• on units such as motor, gear-box etc.

8.5 Notes to Maintenance Manual

From page 29, there are listed charts with execution remark for maintenance and for listing of defects
(hydraulic, mechanical or control system defects)
Maintenance Carried-out by
Remark
......... oh company / date / name
.... ....... .......
.... ....... .......
Remedied: Remedied:
Date / Measure to
Consecutive No. Type of defect Customer WIRTH
operating hours remedy defect
Date / Name Date/ Name
1 ....... ....... ....... ....... .......
2 ....... ....... ....... ....... .......
An uninterrupted listing of maintenance work and defects is obligatory for detection of reasons and
remedy.
During the guarantee period, the acceptance of guarantee

performance depends hereon.
8.6 Operations before / during / after Maintenance

Projecting pressurized oil can cause injuries.
Never work at a pump in operation. Mount and get off the stopped pump using the provided suitable
climbing supports.
• before maintenance
Secure pump and equipment against unintended movement and starting.
Carry out maintenance work only with technically perfect tools suitable for just this type of work.

When working at the electric system or on parts, tools, etc. that are in contact with electric system
parts isolate them from power supply.
Open or remove protective units only at stopped drive or drive secured against unintended starting.
Before cleaning the pump, cover or tape all openings where no water, vapor or detergent may
penetrate for safety and function.
Keep tools, work place and pump clean. Before doing maintenance work, clean all connections and
threaded unions from oil or grease. Do not use any aggressive detergents. Only take non-fluffing
cloths for cleaning.

ATTENTION
Detergents must not attack gaskets, etc. Test detergents for suitability, before using them.
DANGER
The electric system is only splash-proof. When cleaning the pump with a HP cleaner do not
spray electric parts with the lance.
Penetrating water can otherwise damage the electric system of the pump. In an extreme case,
this can even cause sudden, unintended operational movements. Never direct the water jet
onto electrical contacts and modules.
After cleaning, check all lines for leakages, loose joints, abrasion and defects. Immediately eliminate
detected faults.
Re-usable parts are cleaned and then dried with a non-fluffing cloth or dry, filtered compressed air of
max. 2 bar.
• during maintenance
ATTENTION
Only the oils and lubricants prescribed by WIRTH and/or being suitable for the purpose may
be used.
Non-observation will make any guarantee claim for the pump null and void.
Check oil levels.

Make oil changes.
NOTE
Carry out oil changes with power pack at operation temperature to enable a better run-off of
any dirt in the oil.
NOTE
Catch oils and lubricants in a suitable bin and dispose them as prescribed.
NOTE
Clean lines, oil measuring rod, etc. only with non-fluffing cloths.
In case of oil losses determine the reason and eliminate it promptly.

When changing oil types thoroughly clean the units with rinsing oil.

ATTENTION
A change-over from synthetic oil to mineral oil and vice-versa is not permitted.
Renew sealing elements when mounting.

Exchange defective hydraulic lines, pipes and hoses.
Re-tighten threaded-unions only in pressure-less condition.
When mounting pre-fill the hydraulic pumps and motors through the leakage line connection.
ATTENTION
It is forbidden to modify set values of pressure limiting valves without the prior approval of
WIRTH.
Check fastening and securing elements and renew them, if required so.
Exchange defective components.
Clean filling ports and lubricating nipples before filling. After filling, shut ports immediately.
Remove protective caps and coverings only just before starting work.
When removing plugs, set dust protection caps on the plugs and the machine.
• after maintenance
Check all units for tightness.

Mount the protective devices and carry out a functioning test of the pump.
NOTE
When disposing detergents, oil-containing components and waste oil, consider the
environmental protection rules.

8.7 Hydraulic Hoses and Hose Lines

DANGER
Repairs of hydraulic hoses and hose lines are not permitted!
Check all hoses, hose lines and threaded-unions regularly, at least once (1 x) per year for leakages
and externally visible defects!
Remove defective parts immediately!
Projecting oil can cause injuries and fires.
Even with correct storing and admissible straining, hoses and hose lines are subject to natural aging.
This limits their duration of use.
Improper storing, mechanical defects and inadmissible straining are the most frequent reasons of
failure.
The duration of use of a hose line should not exceed six (6) years, including a storing time of
maximum two years (look at manufacturing date on the hoses!).
A use at the limit of admissible straining can reduce the duration of utilization (e.g. high temperatures,
frequent movements, extremely high impulse frequencies, multiple shift operation).
Hoses and hose lines should be replaced, if detecting the following when inspecting:
• damage to the outer coat continued down to the inner layer
(e.g. abrasion points, cuts and cracks);
• brittling of the outer coat (cracks of the hose material);
• a deformation that does not correspond to the natural shape of the hose or the line, both in
pressure-less and pressurized condition or if bending, e.g. separation of the coats, formation of
bubbles
• leakages
• non-observation of installation requirements
• damage to or deformation of a hose fitting reducing rigidity of the fitting or of the connection
hose/fitting
• wriggling of the hose out of the fitting;

• corrosion of fitting deteriorating function and rigidity
• excess of storing and utilization duration.
When exchanging hoses and hose lines, exclusively use original spare parts.
• Lay and mount hoses and lines professionally. Do not change connections by mistake.

8.8 Lubricants / Oils

The lubricants specified below do not contain any statement as to their quality.
Equivalent lubricants of other mineral oil companies may also be used.
The designation of oils can be modified by the mineral oil companies.

Selection of oils should be made in consideration of the utilization conditions
(e.g. summer / winter).
ATTENTION
Before each start-up, make a check of all oil levels and lubrication of all points to be
lubricated.
• Gearing oil
Gearing oil for lubricating the drive system
Operating temperature range: -20oC to +52oC DIN 51517 part 3 ISO-VG 220
- 1°C to +68°C DIN 51517 part 3 ISO-VG 320
Cleanliness class after

• NAS 1638 class 8
or
• ISO 4406 (c) class 19/17/14
Mineral
oil acc.to
ARAL BP FUCHS ELF ESSO KLÜBER MOBIL SHELL
DIN
51517
REDUCTELF
SP 220 SPARTAN
CLP 220 Degol Energol Compound LAMORA Mobilgear Omala
GR-XP 220 106 VG 220 ELF EP 220 220 630 Oil 220
BG 220
KASSILLA
220
REDUCTELF
SP 320
Degol Energol Compound SPARTAN LAMORA Mobilgear Omala
CLP 320 BG 320 108 VG 220 ELF EP 320 320
GR-XP 320 632 Oil 320
KASSILLA
320

(optionally for chain drive system)
Gearing oil for lubricating the chain drive
Mineral
oil acc.to
ARAL BP FUCHS ELF ESSO KLÜBER MOBIL SHELL
DIN
51517
REDUCTELF
SP 100 SPARTAN
CLP 100 Degol Energol Compound LAMORA Mobilgear Omala
GR-XP 100 103 VG 100 ELF EP 100 100 627 Oil 100
BG 100
KASSILLA
100
• Grease
Grease acc.
to ARAL BP FUCHS ELF ESSO KLÜBER MOBIL SHELL
DIN 51825
NLGI class. 2
utilization
temperature. –
Aralub Energrease RENOLIT BEACON Mobillux Alvania
20°C to +120°C
LS-EP 2 FEP Epexa 2 Centoplex 2 EP 2 EP (LF) 2
HLP 2 EP 2
KP
2K-20

8.9 Torque and Tensioning Setting Values
8.9.1 Screw Tightening Torque (Nm)
TPK 800 / 1000
Nm
Hydraulic valve closure (M27) - 1050
Clamping element (crosshead rod/piston rod) (M20) - 340
Piston to piston rod (M36) - 1700
Crosshead rod to crosshead (M20) – 340
Pressure connector (M12) – 70
Suction valve to discharge valve housing (M36x3) – 3400
Discharge valve housing to gearbox frame (M36x3) – 3400
8.9.2 Pressure Values for Hydraulic Tools
Hydraulic pressure (barg)
tensioning de-tensioning
Valve closure 1450 1470
Liner clamping flange 1400 1450 © WIRTH Maschinen- und Bohrgeräte-Fabrik GmbH - Änderungen vorbehalten / Subject to modifications
ATTENTION
The max. allowable de-tensioning pressure shall not exceed 1500 bar. At higher pressures,
the studs are subject to excess elongation and must not be re-used.

8.10 Maintenance
Before exchanging the wear parts attention should be paid in any case to that the fluid end has been
depressurised. Moreover, before installing new gaskets, clean the matching sealing surfaces.
NOTE
‚Right’ side and ‚left’ side means: looking from the pump power end to the fluid end.
NOTE
The drawing indications are not order bound, but serve for illustration, only .

8.10.1 Removal and Installation of Valve Closures

(drawing B0023292) [(A2406749)]
8.10.1.1 Removal
Depressurise the fluid end.
Turn out protective cap (11) .
Install complete valve closure (14) and turn until stop, then back by ¼ of a turn.
Connect the hydraulic hose with the plug-type coupling of the hand pump
(21032541) to the snap-on connector on the valve closure [(09)] .
Apply hydraulic pressure of 1470 bar using the hand pump.
Loosen inner threaded bushing (10) using a mounting rod (Ø 20).
Discharge hydraulic pressure on hand pump, remove plug-type coupling.
Unscrew complete valve closure (14) and threaded bushing (10).
Screw eyebolt M30 into valve insert cover (15) and dismount valve insert cover.
(Use auxiliary crane, if required so).
NOTE
The valve components are now accessible for inspection and/or replacement.
B0023292 A2101298
11
[(09)]

14
10
15
18

8.10.1.2 Installation
Clean the sealing surfaces on the valve insert cover, and sealing ring.
Inspect the sealing ring (18) and renew, if damaged.
Install valve insert cover using eyebolt.
Screw on threaded bushing (10) until stop, using the assembly rod.
Screw on valve closure (14) until stop, then back by ¼ of a turn.
Install insert cover (16) complete with sealing ring (11) and threaded closure (10).
Connect hydraulic hose of hand pump on valve closure using snap-on connector
[(09)].
Pressurize the hydraulic piston applying 1450 bar. This way, the flange screws (12) are
stretched by a minute amount and push the upper part away from the valve body.
D Tighten threaded bushing (10) using the assembly rod.
Depressurise the hydraulic piston. The residual tension induced into the flange retaining
studs (12) by stretching them will pull the complete upper and lower assemblies
together, thereby concentrating all of the closing force on the sealing ring.
D Disconnect the hydraulic hose from the snap-on connector.
D Screw out valve closure (14) and screw down protective cap (11) .
ATTENTION
To avoid damaging to the threads and sealing surfaces, the valve closures must be re-
tightened, applying the above procedure. After two hours running time, repeat the tightening
procedure. Periodic checks must also be made and the closures should be tightened as
required.
21032541
Manometer
Pressure gauge
A2305864

8.10.2 Removal and Installation of Valve Seats

(drawing B0023292)
8.10.2.1 Removal
Remove the valve closure as described in 8.10.1.1 .
Remove the complete valve (16) , i.e. cone and pressure spring. The complete valve
can be removed by hand.
Re-install valve insert cover (15) and threaded bushing (10) and tighten with the torque
bar. It is not necessary to tighten with the hydraulic stud tensioner.
DANGER
Re-placement of the valve insert cover is a precaution measure to prevent the valve
seat from flying out when it is expelled by the hydraulic pressure. This safety
measure must be adhered to, in any case.
Connect hand pump to snap-on connector (20) and increase the pressure
(max. 1500 bar) until the valve seat is expelled.
Depressurise and remove hand pump connector from snap-on connector.
Dismount threaded bushing (10) and valve insert cover (15) as well as the valve seat.
B0023292
10
15
16
20

ATTENTION
Prior to installing the valve seat, thoroughly clean the tapered surface of the seat and
the mating taper in the valve body.
Insert two new O-rings into the grooves in the valve seat.
Ensure that the mating tapered surfaces are clean and dry.
ATTENTION
The tapered surfaces or the O-rings must never have any contact to oil or grease.
Insert the valve seats into the valve body and tap them home using a piece of wood
(or similar soft material) and a hammer.

8.10.3 Turning of Mud Pump by Hand

(Belt drive - drawing B0015476) [chain drive - drawing B0022420]
The mud pump can be turned by hand in order to assist with maintenance routines and operational
piston / liner changes.
The procedure is as follows:

Isolate the mud pump from the electricity supply.
Depressurise and drain down the fluid end to ensure that the pump is not working against a fluid
pressure whilst it is being turned.
Unscrew the cover plate (15) - [36] , that is located at the right and left protective hood of the
belt drive to get access to the turning device (23) - [49] .
In the turning device there is plugged in a 300 mm long extension piece (# 21019638) with a 1“
square piece. This will turn the main drive shaft through the gear to the crosshead and the
crosshead rod.
After maintenance / liner change, ensure that both the extension piece has been removed and
the cover plate (15) - [36] , and all fastening bolts have been re-placed and tightened.

Belt drive
B0015476
15
B0015476-1
23
Chain drive
B0022420
36, 49

8.10.4 Removal and Installation of Pistons & Piston Rods

(drawing B0022574)
8.10.4.1 Removal
Lift the hinged cover plate allowing access to the piston rod chamber.
Remove the couplings (05) which clamp the piston rod and crosshead rod together.
Move the crosshead rod slightly to the rear so that the link piece (04) can be removed.
DANGER
Never power up the drive main motors to move the crosshead rod. Always rotate
pump manually with socket wrench as described in chapter 8.10.3.
Remove the link piece (04) and the end cover plate (B0022692 - 12). It is not
necessary to disconnect the cooling water supply hose from the link piece.
Move the crosshead rod (02) forward until it touches the piston rod (03)
and use one of the split couplings (05) to lock them together.
Move the crosshead rod (02) as far back as it will go. This will pull the piston rod (03)
with it until the piston is drawn clear off the cylinder.
Disconnect the couplings (05) and remove the piston rod (03) using the on board
maintenance crane and certified slings.
hinged cover plate
B0022692 – 12
B0022574
02 05 04 05 03

Install new sealing ring (10) to the link piece (04) .
Assemble piston to piston rod and tighten end nut (07) at a torque of 1700 Nm.
Grease the piston.
Introduce the piston and piston rod into the cylinder without link piece, paying careful
attention to not to damage any component.
Move the crosshead rod forward until it butts end to end with the piston rod and push the
piston rod into the cylinder far enough to allow the link piece (04) to be assembled once
the crosshead rod has been withdrawn.
Move the crosshead rod back a sufficient distance and insert the link piece (04). Oil the
clamping bolts on the two split couplings (05) and torque up to 340 Nm.
Re-place end cover plate (B0022692 - 12) .
Re-place hinged cover plate over piston chamber.
ATTENTION
The end nut (07) has to be replaced after each disassembly of pistons!
B0022574
B0022692 – 12
10
Ma = 1700 Nm
02 05 04 05 03 07

8.10.5 Removal and Installation of Liners

(drawing B0022692)
8.10.5.1 Removal
Remove the piston rods as described previously in chapter 8.10.3.
Connect the hydraulic hand pump to the snap-on connector (09) on the
flange (02) .
Apply a hydraulic pressure of 1450 bar. This will stretch the retaining studs (08)
by a minute amount and take the load off the nuts (04) .
Unscrew the nuts (04) 6x by special wrench (A2301183) .
Release the hydraulic pressure from the system. This removes all tension from the
retaining studs (08) .
Unscrew nuts (03 + 04) as a pair.
Attach flange assembly (02) to pump maintenance crane using a certified sling
(handle 10) without exerting a radial charge on the liner.
Pull clamping flange from liner and dismount it by crane.
Pull liner by pulling device (B0025498) to the rear out of the fluid end and remove it
upwards.
Remove wear ring (B0023292-07) using the pulling device (B0016899).
For lifting the liner out of the pump, use a certified lifting harness.
B0022692
09 10
03 04 05 02 08
04 02 08

Clean the liner, fit a new end seal and grease it. Clean and grease the bored surface in
the pump frame that mates with the end of the liner. Replace wear ring with sealing
(B0023292 – 07, 08), if damaged.
Install the liner using a certified sling in conjunction with the pump maintenance crane.
The liner may require tapping in using a hard wooden block and a hammer.
Push the clamping flange (02) ahead and screw-on nuts (03 + 04) .
Tighten nuts (03) until they make firm contact with the hydraulic pistons (05) ; here, the
outer nut (04) must be set back by about 3 - 4 mm.
Connect the hydraulic hand pump to the snap-on connector (09) on the flange (02).
Apply a hydraulic pressure of 1400 bar. This will stretch the upper part of the retaining
studs (08) by a minute amount.
Tighten the nuts (04) using the special wrench (A2301183) .
Release the hydraulic pressure from the system. This will induce a tension in the
retaining studs which will keep the total assembly connected tightly together.
Install the piston rods as described in chapter 8.10.3.2.
B0025498
04
(pulling screw)
05
(split ring)
A2301183
A 2 3 0 11 8 3
B0016899 B0023292
07, 08
B0016899.wmf

8.10.6 Removal and Installation of Pressure Connection

(drawing B0023292)
8.10.6.1 Removal
Ensure that the pressure manifold and discharge pipe lines are depressurised.
Remove all retaining studs (26) on one of the flanges.
Using a large screw driver, carefully pinch the free flange along a distance of about
5 mm so that the two flanges move together.
Remove all studs (26) on the other flange, with the exception of the top two.
Support the weight of the flanges, remove the two remaining studs and withdraw the
flanges as a pair from between the valve housings.
Clean all sealing surfaces.
Spring the O-ring (25) over the lip of the telescopic connection into the ring groove
on flange (23) .
Telescope the two flanges together by pushing one inside the other.
Install an O-ring (25) into each of the ring grooves on the flange surfaces (23 + 24).
Slide the complete assembly between the two valve housings and tighten the retaining
studs (26) on each flange with MA = 70 Nm.
B0023292
24 26 23 25

8.10.7 Drive Mode
8.10.7.1 Belt Drive

With regard to drive of the pump by power belts, reference is made to document I 0002490 in the
Annex.
8.10.7.2 Chain Drive
Lubrication condition:
Lubrication of the chains should be such that all their surfaces are covered with oil, i.e. universal-
joints and brackets must always be humid from oil.
Chain assembly:
All sprockets of a chain drive must be mounted such that a sufficient alignment is ensured during the
entire operation duration. The alignment is regarded as sufficient, if a lateral force is not exerted on
the chain.
The sprocket shafts should largely be in parallel - max. admissible deviation approx. 3° - . Of course,
they also must run impact-free.
Chain tension:
In its idle strand each chain drive needs a certain slack to have a safe and calm running attitude.
The idle strand should have a slack of about 2 to 3 % of the axle distance.
Admissible chain wear:

Due to abrasion between bolts and sleeves of roller chains the chains lengthen. This lengthening may
be max. 3 %. Then the chain should be exchanged. (3 % = 30 mm per meter).
Chains should also be exchanged, when they have visible defects.

8.11 Repair of Mud Pump
NOTE
‚Right’ side and ‚left’ side means: looking from the pump power end to the fluid end.
Repairs or wear checks on the pump (e.g. removal and installation of drive shaft, crankshaft, fluid
end, etc. …) due to a defect or many operation hours, are work beyond the normal scope of
maintenance. This work requires the intervention of a WIRTH specialist. Special tools only available
in the manufacturer’s works are required for it. They will be shipped advancing the technician or be
taken along by him.
Prior to any repairs the mud pump must be isolated from the electricity supply. The fluid end must be
depressurised.
NOTE
We recommend that all bearings and crossheads / slide ways should be inspected at regular
intervals of 12,000 operating hours, or after 4 operating years, at the latest, for defects and
wear limits. If any wear indicates during the regular maintenance intervals, the
recommended period should be reduced.

8.12 Maintenance Chart with Execution Remark

Maintenance Carried-out
Remark
......... Oh Company / Date / Name

Maintenance chart with execution remark
Remark


Remark

Remark

Remark

Remark

8.13 Trouble Shooting Chart

Remedied: Remedied:
Date / Measure for
Cons. No. Type of failure Customer WIRTH
Operating hours remedy of failure
Date / Name Date Name

Trouble shooting chart

Remedied: Remedied:
Date / Measure for


Remedied: Remedied:
Date / Measure for


Remedied: Remedied:
Date / Measure for


Remedied: Remedied:
Date / Measure for

1-08-E - R0 Maintenance - 1000

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Volume I / 8 Maintenance

8.1 General ...............................................................................3

8.10.7.2 Chain Drive .......................................................................27

Survey on Filling Quantities / Maintenance Materials ......................1/1

(Optionally for Belt Drive)

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Rev. Page Description Made by Remark

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DANGER : PERSONAL PROTECTIVE EQUIPMENT (PPE)

ATTENTION WORKING IN INSUFFICIENTLY ILLUMINATED AREAS

THE LAMP TO COMPLY WITH THE REGULATIONS !

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• There may only be charged those persons

• The operator’s permit to work system must be adhered to.

• The fluid end and other pressurized lines must be depressurized.

• The suction and discharge dampener must be depressurized.

• Complete the Maintenance Manual by instructions including supervision and registration

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• Wear personal protective equipment to the required extent and as demanded by

• Keep all safety and caution notes on the pump in mind!

• To carry out maintenance measures a workshop equipment as required by the level of

• Make place and use of fire extinguishers public!

• Consider fire alarm and fire fighting possibilities!

• Staff to be trained, instructed or informed or personnel acting within the scope of a

supervision of an experienced person!

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8.3 Maintenance Intervals

Welding must not be carried out:

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8.5 Notes to Maintenance Manual

During the guarantee period, the acceptance of guarantee

8.6 Operations before / during / after Maintenance

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Check oil levels.

In case of oil losses determine the reason and eliminate it promptly.

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Renew sealing elements when mounting.

Check all units for tightness.

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8.7 Hydraulic Hoses and Hose Lines

Repairs of hydraulic hoses and hose lines are not permitted!

• wriggling of the hose out of the fitting;

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8.8 Lubricants / Oils

Equivalent lubricants of other mineral oil companies may also be used.

The designation of oils can be modified by the mineral oil companies.

Cleanliness class after

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(optionally for chain drive system)

Gearing oil for lubricating the chain drive

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8.9 Torque and Tensioning Setting Values

8.9.1 Screw Tightening Torque (Nm)

TPK 800 / 1000

Hydraulic valve closure (M27) - 1050

Clamping element (crosshead rod/piston rod) (M20) - 340

Piston to piston rod (M36) - 1700

Crosshead rod to crosshead (M20) – 340