American AME0413HD Manuel utilisateur

Factory/Sales Ofﬁce

P.O. Box 640

736 19th Avenue NE

St. Joseph, Minnesota 56374

(888) 299-3412 ~ Toll Free

(320) 363-7273 ~ Phone

(320) 363-7274 ~ Fax

[email protected]

www.american-manufacturing.com

Pump AME0413HD

Operation And Maintenance Manual

7k-0266

Page 2 of 38

Operation And Maintenance Manual

For AME0413HD Pump

Summary:

This is a manual for American Mfg Company AME0413HD vertical quadruplex piston pump

with disc valves.

Alternate valve seat option:

The standard model AME0413HD comes with PPFMC 5260142 Valve seat, Raised face.

Optional valve seat version: PPFMC 1219615 Valve seat, Flat.

Page 3 of 38

Speciﬁcations

Pump Model AME0413HD

Conﬁguration Vertical Quadruplex Piston

Number of Pistons 4

Stroke Length 1.0 Inches (25.4 mm)

Frame Load Rating 1240 lbs. (562.455 kg)

Pump Weight (Average) 80 lbs. (36.29 kg)

Direction of Rotation Either

Internal Gear Rotation 1:1

Intermittent Duty Speed Rating 575 RPM

Continuous Duty Speed Rating 450 RPM

Minimum Speed 390 RPM

Mechanical Efﬁciency 85%

Lubrication System Splash, Gravity Return

Lube Oil Capacity 1 Quart

Lube Oil Type SAE 30

Maximum Fluid Temperature 140°F

Minimum Fluid Temperature 0°F

Standard Suction Size 1.25 Inch NPT

Standard Discharge Size 0.75 Inch NPT

Fluid End Material Cast Iron

Valve Type Disc Valve

Performance Rating

Pump

Model Diameter

Displacement/

REV

Maximum

Pressure

Pump Capacity @ Input Speed (RPM)

390 RPM 400 RPM 425 RPM 450 RPM 575 RPM

Inch mm Gallon Liter PSI kg/cm2gpm lpm gpm lpm gpm lpm gpm lpm gpm lpm

AME0413HD 1.625 41.27 0.036 0.12 550 38.6 14.01 53 14.36 54.35 15.26 57.77 16.16 61.17 20.65 78.17

AME0413HD Piston Pump Data

6.7 BHP Continuous Duty (8.5 BHP Intermittent Duty)

Horsepower is based on 85 or 90% efﬁciency. Actual application horsepower

requirements can be calculated using this equation: BHP = (GPM*PSI)/(1714*0.85

or 0.90) Pump capacities listed are based on 100% volumetric efﬁciency.

This document contains American Mfg Company proprietary and conﬁdential

information. It is loaned for limited purposes only and remains the property of

American Mfg Company. It may not be reproduced in whole or part or disclosed

to third parties without the prior written consent of American Mfg Company. The

document is to be returned to American Mfg Company upon request and in all

events upon completion of the use for which it was used.

Speciﬁcations subject to change without notice.

Factory/Sales Ofﬁce

P.O. Box 640

736 19th Avenue NE

St. Joseph, Minnesota 56374

(888) 299-3412 ~ Toll Free

(320) 363-7274 ~ Fax

(320) 363-7273 ~ Phone

[email protected]

www.american-manufacturing.com

7k-0266

Page 4 of 38

Table Of Contents

1.0 Important Safety Instructions................................................................................ 6

2.0 AME0413HD Pump Features.............................................................................. 7

3.0 Storage Instructions........................................................................................... 8

3.1 Short Term Storage........................................................................................... 8

3.2 Short Term Storage for Severe Environments........................................................... 8

3.3 Returning a Stored Pump to Operation.................................................................. 9

3.4 Precautions During Freezing Weather................................................................... 9

4.0 Installation Guidelines........................................................................................ 10

4.1 General Location.............................................................................................. 10

4.2 Mounting Pump to Foundation and Power Source................................................... 10

4.3 Suction Piping Recommendations......................................................................... 10

4.4 Discharge Piping Recommendations..................................................................... 11

5.0 How to Start a Pump......................................................................................... 13

6.0 Lubrication of Power End.................................................................................... 14

6.1 Recommended Lubricants................................................................................... 14

6.2 Oil Changes................................................................................................... 14

7.0 Inspection and Preventative Maintenance Chart...................................................... 16

8.0 Components Parts List........................................................................................ 17

8.1 Power Frame Components................................................................................. 18

8.2 Fluid End Components....................................................................................... 19

9.0 Service Procedures........................................................................................... 20

9.1 Replacing Cup Pistons....................................................................................... 20

9.2 Replacing Suction and Discharge Valves............................................................... 23

9.3 Servicing the Power End.................................................................................... 25

10.0 Fastener Torque Requirements.............................................................................. 28

11.0 Critical Clearances........................................................................................... 29

12.0 Trouble-Shooting Pumps..................................................................................... 30

13.0 Ordering Parts................................................................................................. 33

14.0 Pump Mounting Dimensions................................................................................ 34

15.0 Glossary of Commonly Used Terms...................................................................... 35

16.0 Reference Information........................................................................................ 37

17.0 Maintenance Log............................................................................................. 38

Page 5 of 38

List of Figures and Charts

Table 1 MAWP for Steel Pipe........................................................................................ 11

Table 2 Lubricant Recommendations................................................................................ 15

Table 3 Maintenance Chart........................................................................................... 16

Table 4 Component Part List.......................................................................................... 17

Table 5 Torque Values for Critical Pump Fasteners.............................................................. 28

Table 6 Clearance Chart.............................................................................................. 29

Figure 1 AME0413HD Pump Assembly............................................................................ 7

Figure 2 Power End Components..................................................................................... 18

Figure 3 Fluid End Components....................................................................................... 19

Figure 4 Valve Seat Removal Tool.................................................................................... 24

Figure 5 Pump Mounting Dimensions................................................................................ 34

Page 6 of 38

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.

SHUT DOWN OR DISENGAGE the pump and all accessory equipment before attempting any type of service.

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.

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.

NEVER OPERATE THE PUMP WITHOUT A PRESSURE RELIEF VALVE, rupture disc, or other type of properly sized

over pressure safety device installed.

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.

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.

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.

ALWAYS USE GUARDS on all belt drives, couplings, and shafts. Guards can prevent personnel from becoming

entangled and injured by rotating and reciprocating parts.

USE EXTREME CAUTION WITH SOLVENTS used to clean or degrease equipment. Most solvents are highly

ﬂammable and toxic. Observe all safety instructions on packaging.

FOLLOW NORMAL ENVIRONMENTAL GUIDELINES WHEN ﬂuids, lubricants, or solvents are disposed of or

spilled.

NEVER MODIFY THE PUMP to perform beyond its rated speciﬁcations without proper authorization in writing

from AMERICAN MFG COMPANY.

Page 7 of 38

2.0 AME0413HD Pump Features

The AME0413HD drive shaft standard end comes with 1-1/8” diameter shaft and 1/4” square keyway.

Figure 1: AME0413HD Pump Assembly

Corrosion resistant disc

valves are stacked in

the fluid end using

O-ring seals for easy

servic e

Hardened steel wrist

pins are ground to a

mirror finish for a

precise fi t

Spring-loaded oil

seals keep oil in and

contaminants out

1-1/8” diameter straight

keyed mounting

Polished ceramic

cylinders provide

unsurpassed wear and

corrosion resistanc e

Aluminum alloy

connecting rods have

wrist pin bushings and

split insert bearings

Heavy duty , oversize

ball bearings

Page 8 of 38

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. 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 6.2), 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.

Page 9 of 38

3.3 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 6.2) 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.

3.4 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

the bottom plugs and cylinder covers from the ﬂuid cylinder. Drain the liquid from the discharge valves ﬁrst and then

the suction valves by lifting the valves. This ensures all ﬂuid to be 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.

Page 10 of 38

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 AME0413HD pump must be mounted in a vertical position only. Secure the pump to the mounting surface using

the holes provided in the pump base. The design of the AME0413HD pump allows the drive shaft to be rotated in

either direction. 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

maunufacturer 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.

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

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