LICENSE NO.

7K-0071

ZYF-1300 ZYF-1600
MUD PUMP
OPERATION & MAINTENANCE MANUAL
 INDEX
Preface--------------------------------------------------------------------------------------------3
1Summarize-----------------------------------------------------------------------------------------4
2 Technical Parameter------------------------------------------------------------------------------4
2.1 ZYF-1300\1600 Mud Pumps Specification------------------------------------------------- 4
2.2 ZYF-1300\1600 Mud Pumps General Dimensions ----------------------------------------5
3 Structure Features--------------------------------------------------------------------------------5
3.1 Power End features----------------------------------------------------------------------------5
3.2 Fluid End features-----------------------------------------------------------------------------6
4 Installation of New Pump-----------------------------------------------------------------------7
4.1 Setting the Pump-------------------------------------------------------------------------------7
4.2 Land Installations------------------------------------------------------------------------------8
4.3 Permanent Installations------------------------------------------------------------------------8
4.4 Installation of The Drive-----------------------------------------------------------------------9
4.4.1 V-Belt Drives---------------------------------------------------------------------------------9
4.4.2 Chain Drives---------------------------------------------------------------------------------10
5 Suction System Requirements------------------------------------------------------------------11
6 Preparation of Power End----------------------------------------------------------------------12
6.1 Power End Lubrication-----------------------------------------------------------------------12
6.2 Installation of Crosshead Extension Rods and Diaphragm Stuffing Box Seals --------12
7 Pistons and Liner Cooling System-------------------------------------------------------------14
8 Assembly of Fluid end Parts--------------------------------------------------------------------15
9Lubrication----------------------------------------------------------------------------------------19
9.1 Minimum Operating Speed-------------------------------------------------------------------19
9.2 Controlled Flow Splash System--------------------------------------------------------------20
9.3 Total Pressure Lubrication System-----------------------------------------------------------20
9.4 Maintenance of the Lubrication System-----------------------------------------------------22
10Maintenance-------------------------------------------------------------------------------- -----24
10.1Power End-------------------------------------------------------------------------------------24
10.2Pinion Shaft Assembly------------------------------------------------------------------------26
10.3Crank shaft Assembly-------------------------------------------------------------------------27
10.4 Installation of Crosshead Guides------------------------------------------------------------31
10.5 Installation of Crossheads--------------------------------------------------------------------32
10.6 Checking Crosshead Alignment-------------------------------------------------------------33
10.7Fluid End Maintenance------------------------------------------------------------------------34

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10.8 Welding and Repairs------------------------------------------------------------------------38
10.9 Repairs to Valve Pot Cover Bore----------------------------------------------------------38
10.10 Operating Maintenance--------------------------------------------------------------------39
10.11Troubleshooting-----------------------------------------------------------------------------43
11 Opproximate Weight of Pump Assemblies------------------------------------------------- -45
12 Storage-------------------------------------------------------------------------------------------45
13 Explains For Order -----------------------------------------------------------------------------45
13.1 Provided Range of Mud Pump--------------------------------------------------------------45
13.2 Style of Mud Pump---------------------------------------------------------------------------46
14 The List of Tools ,Spare parts, Expendables and Bearing----------------------------------46
15 Appendix: ZYF-1300\1600 Mud Pump Parts List-------------------------------------------50

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 PREFACE
This manual has been prepared according to drawings ZYZJPEC 2006. This manual is
provided for guidance of those who wish to install, repair, maintain, or adjust the ZYF series
pump covered herein. This information has been prepared with a basic viewpoint to give
accurate and concise data needed to perform minor adjustments as well as major overhauls.
This information is not elementary, as it is intended for operators and servicemen who are
familiar with drilling equipment in general. It is not intended, nor would it be possible in
such limited space, to cover every possible condition which may be encountered. Always
use good, sound mechanical practices and safety precautions.
All specifications are in accordance with Engineering designs and should be adhered to in
all repairs. Operation and maintenance information on equipment other than ZYF is taken in
part from the various manufacturers’ manuals.
ZYZJPEC reserves the right to discontinue models at any time, or change specifications
or design of any model without notice and without incurring any obligation.

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1 Summarize
The ZYF－1300/1600 mud pump are designed by and made in Henan ZYZJ Petroleum
Equipment Co., Ltd ,mud pump have been completely assembled and test operated under
pressure before being shipped to the field. Unless otherwise instructed, the lubrication is
drained from the power end. Before putting the pump into service, the following
precautions and operations must be performed or checked.
2 Technical Parameter
2.1 ZYF-1300 And ZYF-1600 Mud Pumps Specification
Table 1
1 Model ZYF-1300 ZYF-1600
2 Type Triplex Single Acting Mud Pump
3 Horse Power Rating HP(kW) 1300（960） 1600（1180）
4 Speed Rating spm (min-1) 120
5 Piston Stroke in（mm） 12（304.8）
6 Type Gear Herringbone
7 Gear Ratio 4.206
8 Rated Speed Of Dirve Shaft rpm (r/min) 505
9 Maximum Working Pressure psi (MPa) 4975(34.3)
10 Valve Pots 7# (API)
11 Maximum Bore Size in（mm） 7（Φ177.8）
12 Maximum Flow U.S.gpm（L/S） 719.8（45.41）
13 Maximum Pressure For Max. Liner psi (MPa) 2754(18.99) 3392(23.39)
14 Suction Inlet in (mm) 12 (Φ305)
15 Discharge Outlet in (mm) 5 1/8(Φ130)
16 Pinion Shaft Size in（mm） 8.5（Φ215.9）
17 Keys in（mm） 2×2×11 3/8（50.8×50.8×288.9）
18 Outline Size(L×W×H) in（mm） 174.25×95×79（4426×2413×2004）
19 Total Weight lbs（kg） 555,383（252,21） 571,04（25732）

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2.2 ZYF-1300 And ZYF-1600 Mud Pumps General Dimensions
Table 2
General Dimensions
ZYF-1300 ZYF-1600
A 1540 1540
B 1722 1722
C 1222 1222
D 1424 1424
E 344 344
F 1266 1266
G 1462.65 1462.65
H 1880 1880
J 2693 2693
L 215.9 215.9
Key 50.8×25.4 50.8×25.4
M 1614.9 1614.9
N 2004 2004
P 1413.7 1413.7
Q 4426 4426
R 497.25 497.25
S 256 256
T 419.1 419.1
U 348.5 348.5
V 767.6 767.6
W 324 324
X 489 489
Z 2057.4 2057.4 Fig.1
3 Structure Features
3.1 Power End Features
a. The Frame The frame is made of welded steel plate and stress relief treated to
obtain the good rigidity and high strength. The place where the crankshaft bearing is fitted is
strengthened by using ribbed plates. The frame is furnished with the necessary oil basin and
oil way system for cooling and lubricating purpose.
b. The Pinion Shaft The pinion shaft is made of forged alloy steel on which a
herringbone gear with the medium-hard tooth surface is machined. For easy maintenance,
the single row radial long cylindrical roller bearing with inner ring (without sides) is used.

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The both ends of the pinion shaft extend out, so that the sheave or the sprocket can be
mounted on either end.
c. The Crankshaft The crankshaft is made of cast alloy steel and furnished with
herringbone gear, connecting rod and bearing. The tooth form of the big-geared ring is
herringbone gear. The gear bore and the crankshaft surfaces are interference fitted and they
are both fastened with bolts and lock nuts. The big end of the connecting rod is mounted on
three eccentric straps of the crankshaft through single row short cylindrical roller bearings
and the small end on the crosshead pin through double row long cylindrical roller bearing.
Double row radial spherical roller bearings are mounted at both ends of the crankshaft.
d. The Crosshead And Crosshead Guide The crosshead and crosshead guide are
made of homebred meehanite cast iron featured by good abrasion resistance and long
service life. Upper and lower guides are used for mud pump, so that the concentricity can be
adjusted by adding shims beneath the lower guide. The connection between the crosshead
and the extension rod is made by using bolted flange. The rigid connection ensures the
concentricity of the crosshead and the extension rod. The coupling is used for connecting
the extension rod to the piston rod. The light-weight coupling enables the extension rod and
the piston rod to connect to each other easily and reliably.
e. The Extension Rod Packing The extension rod packing is duplex seal structure to
provide the good seal result.
f. The Power End The power end uses the combined lubricating system of forced
lubrication and splash lubrication.
3.2 Fluid End Features
a. Cylinders Cylinders are made of forged alloy steel, three cylinders of each pump are
interchangeable. Valve-over-valve (through type cylinder) design reduces the cylinder
volume and promotes the volumetric efficiency. At customers request, the cylinder surface
may be nickel plated to improve the abrasion resistance.
Discharge pulsation dampener, shear relief valve and discharge strainer are furnished at
the outlet. ZYF-1300 and ZYF-1600 pump suction inlet is furnished with 12"flange.
b. Valve Assembly The suction valve and the discharge valve for ZYF-1300 and
ZYF-1600 mud pumps are interchangeable. ZYF-1300 and ZYF-1600 mud pump uses API
7# valve pots.
c. Liners Bi-metal liners are used. The sleeve is made of wear-resistant cast iron, the
surface hardness is HRC60～65. Therefore, liners feature wear resistance, corrosion
resistance and high surface finish. Liners are put in from the liner chamber in the front of
the frame and fixed with liner thread ring , liner lock ,bolt and wear plate when installing.

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 d. Pistons And Piston Rods They are slide fitted, sealed with rubber seal ring and
finally fastened with lock nuts to prevent the piston from looseness and to play a role in
sealing.
Cylinders, liners, pistons, valves, valve seats, valve springs, seal rings, valve pot covers,
thread rings and cylinder heads at the fluid end of ZYF-1300 and ZYF-1600 mud pumps are
all interchangeable.
e. Spraying System The spraying system consists mainly of spray pump, cooling
water box, and spray pipe, the function is to cool and rinse liners and pistons to promote
their service life.
The centrifugal spray pump can be driven by a sheave mounted on the input shaft
extension end or a separate motor and cooled and lubricated by water.
The durable fixed spray pipe is used. The spray pipe is mounted on the liner end cover
and the frame. Nozzle is face to the piston end so that the lubricating-cooling fluid can rinse
the contact surface between the piston and liner all the time.
f. Lubricating System The power end uses the combined lubricating system of forced
lubrication and splash lubrication. The pressure oil is conveyed through lubricating pipeline,
crosshead, extension rod, crosshead guide and all bearings by a gear oil pump within the oil
box to realize the forced lubrication. The working condition of the gear oil pump may be
understood from the pressure gauge behind the frame.
g. Charging System To prevent the air lock occurring for low pump inlet pressure,
every mud pump should be furnished with a complete charging system. It consists of
charging pump，pump base, butterfly valve and corresponding manifold. Mounted on the
suction manifold of the mud pump, the charging pump is driven by the special purpose
motor or the input shaft of the mud pump through V-belts to reduce the power consumption.
4 Installation Of New Pump
Your pump has been completely assembled and test operated under pressure before
being shipped to the field. Unless otherwise instructed, the lubrication is drained from the
power end. Before putting the pump into service, the following precautions and operations
must be performed or checked.
In order to prevent personal injury during the performance of any maintenance
or inspection procedures, this equipment MUST BE SHUT DOWN AND NOT
OPERATING and all safety devices on prime movers, drives, etc.，MUST BE IN THE
SAFE POSITION.
4.1 Setting The Pump
The skid under the ZYF pumps are suitable for most any type of installation. It should

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be noted, however, that the box type construction of the power frame has high resistance to
bending but relatively less resistance against twist. Therefore, the support under the pump
must be level and adequate to support the weight and operating forces exerted by the pump.
4.2 Land Installations
In land installations, a mat of 76mm × 305mm boards laid side crosswise to the pump
skids for the entire length, or at a minimum，at the points indicated in Fig. 2, is usually
sufficient. The boards should be a few feet wider than the width of the pump skid runners.
Wet or marshy locations may require a more stable foundation.

Fig. 2
4.3 Permanent Installations
On permanent installations such as barge, platform, structural base, or concrete slab,
where pump skids are bolted down, it is essential that the skids be properly shimmed to
prevent possibility of twisting or distorting the power frame, the pump skids must sit solid
on all shim points with bolts loose.
On barge installations, the pump skids are generally bolted down to T-beams running
parallel and in line with the pump skids. Install shims at points shown in Fig. 2 and 3 and
observe caution of proper shimming to prevent twist or distortion.
The shims on all installations should extend the full width of the skid beam flanges and
have a minimum length of 12" (305mm).
On installations where the power unit or electric motor is mounted integrally with the
pump skids, the preferred installation would be to set the pump package on the T-beams
skids and provide retention blocks rather than bolts to hold it in place, This will allow the
pump to float and minimize the transfer of barge deck or platform distortion into the frame.

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 Fig. 3
4.4 Installation Of The Drive
The drive between the mud pumps and the power source, whether V-belts or
multiwidth chains, should be installed with the greatest care to assure maximum operating
life with minimum of unexpected or undesirable shutdowns due to drive failures.
When installing the drive sheave of sprocket, make sure all grease or rust preventative
is removed from the shaft and the bore of the drive. Remove all burrs or rough spots from
the shaft, key, and keyway. Fit key to the keyways in both the shaft and drive and install key
into shaft keyway.
Coat pinion shaft with a light coating of anti-seize compound or light oil and install the
drive sheave or sprocket hub. Tighten hub bolts as indicated below:
When a wrench or length of pipe is used to increase leverage in tightening draw-up
bolts, it is imperative to adhere to the wrench torque values given in the chart below. This
adherence is important, because in mounting the hub, the tightening force on the bolts is
multiplied many times by the wedging action of the tapered surface. This action compresses
the hub for a snug fit on the shaft. If the bolt tightening forces are extreme, bursting pressure
is created in the hub of the mounted pulley, this pressure may cause the pulley to crack. The
hub bolts should always be tightened alternately and progressively.
Table 3
OD Wrench Torque Wrench Length Wrench Pull
Type
Hub﹡ N.m mm N

ZYF-1300 W 813 900 900

ZYF-1600 W 813 900 900

4.4.1 V-Belt Drives

a. Check sheave groove condition.

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 Before installing the V-belts, check sheave grooves for wear. Worn or rounded grooves
will destroy V-belts rapidly. The sidewalls must be straight. Sheave grooves must be free of
dirt, rust or other extrusions that could damage the V-belts.
b. Check sheave alignment.
The final alignment of the V-belt sheaves should be checked after the V-belts have
been installed and adjusted to their operating tension. If the sides of the sheaves are of equal
distance from the centerline of the groove, check alignment by stretching TWO strings (fish
line or piano wire preferred) along one side of the two sheaves, one above and one below
the centerline, and moving one of the sheaves until the strings touch four points on the side
of the sheave rims. This will determine that the centerline of the drives is parallel and the
faces of the sheaves are square.
c. Adjust V-belt for proper tension.
Adjust the belt tension by moving the sheaves apart until all of the sag has just been
eliminated from the tight side of the belt and some of the belts on the slack side. Then
increase the centers approximately 13mm (1/2") for each 2540mm (100") center distance.
Example: On 3l80mm (150") center, move pump and additional 19mm (3/4").
* NOTE: DO NOT OBTAIN BELT TENSION BY PIICKING UP END OF PUMP
AND ALLOWING BELTS TO TIGHTEN UNDER WEIGHT OF PUMP AS END IS
BEING LOWERED TO THE GROUND.
4.4.2 Chain Drives
a. Installation
Proper installation and maintenance of the sprocket and chain drives are essential if
good service life is to be obtained, since many factors, such as chain width, center distances,
speeds, and loads must be considered when determining the allowable tolerance for sprocket
alignment, no good ‘rule of thumb’ can be applied. The chain alignment must simply be
held as nearly perfect as possible. A more precise alignment can be made by stretching two
steel wires (piano wire) along one face of the two sprockets, one above and one below the
centerline, and moving one of the sprockets until the wires touch at four points. This will
determine that the centerlines of the drives are parallel and the faces of the sprockets are
square.
b. Drive chain lubrication
The pump drive chain lubrication system on the majority of ZYF-series pumps is an
independent system having its own oil pump, reservoir, and drive. Fill chain case to the
indicated level with a non-detergent oil as follows:
Ambient temperature above 32° F (0℃) SAE-30/N100

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 Ambient temperature below 32° F (0℃) SAE-20/N68
For temperatures below 0° F, consult a reputable lubrication dealer for
recommendations.
REFER TO 9.4 Maintenance of the Lubrication System Lubrication Specifications
for approved lubricants and additional specifications. If any discrepancy exists between the
recommendations in this manual and the General Lubrication Bulletin (If the pump has the
bulletin), those in the Lubrication Bulletin will take precedence.
Since this is an independent system it will require the same maintenance or service
attention employed on any other piece of machinery, including:
☆ Daily check of oil level.
☆ Daily check on condition of oil.
☆ Frequent check on oil pressure. (5~15 psi) (0.352 ~1.06 kg/cm2)
☆ Volume of oil being applied to chain.
☆ Condition of nozzles in spray tube.
☆ Condition of oil pump drive (V-belts or chain)
* NOTE: Oil pressure may be adjusted with the pressure relief adjusting screw
on the rear of the pump housing. Pressure drops may also indicate suction and
discharge filter screens need cleaning.
5 Suction System Requirements
Individual installation conditions will dictate the design of the suction system. The
suction of the ZYF-series pumps must have a positive head (pressure) for satisfactory
performance. The optimum suction manifold pressure is 20~30 psi (0.14~0.2lMPa) for
maximum volumetric efficiency and expendable parts life. This head pressure is best
supplied by a 5 ×6 centrifugal pump with 40 hp 1150 rpm electric motor. This type of drive
requires a device to automatically start and stop the centrifugal pump motor simultaneously
with the triplex pump. On DC electric powered rigs a signal can usually be supplied from
the DC control panel to energize a magnetic starter when the mud pump clutch air line will
provide a set of contacts for energizing the magnetic starter when clutch is engaged.
The charging pump can also be belt driven from the triplex pinion shaft charging type
of drive is not as efficient at slow speeds with viscous fluids.
Under some conditions the ZYF-Series pumps may be operated without a charging
pump, provided the fluid level in mud pits is higher than the top of the liners, fluid being
pumped is low viscosity and suction line must be short, straight and of at least the same
diameter as suction manifold inlet.
The suction lines should be piped with valve arrangements so the charging pump can

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be by-passed so operation can be continued in event of charging pump failure or for
maintenance. Operation without a charging pump can be improved by replacing the suction
valve springs with a weaker spring.
Suction desurgers are a very effective aid for complete filling of the liners and
dampening pulsations suction line which results in a smoother flow in the discharge line.
*CAUTION :Do not pipe the return line from the shear relief valve back into the
suction system as a relief valve operation will cause a sudden pressure rise in the
system vastly greater than the system pressure ratings, resulting in damage to
manifold, suction desurger and centrifugal pump.
6 Preparation of Power End
Your pump has been completely assembled and test operated before being shipped to
the field. Unless otherwise instructed, the lubrication is drained from the power end, and the
expendables are removed from the fluid end for storage protection. Before operating the
pump, the following must be performed or checked.
6.1 Power End Lubrication
Before installing lubricant, open inspection door in cover and check oil reservoir for
possible accumulation of condensation, etc., and drain and flush by removing the pipe plugs
on each side of the pump. Refer Item 2. Fig. 6.
Add the proper type and quantity of lubrication in the power end. Refer to 9.4
Maintenance Of The Lubrication System Lubrication Specifications.
Recheck oil level after pump has operated for a period of 15 minutes, Shut pump down
and allow approximately five minutes for the oil level to equalize. Check at oil level gauge,
Item 1. Fig. 6. It is usually necessary for a few more gallons of oil to be added due to a
certain amount being retained in the crosshead area and frame cavities.
6.2 Installation Of Crosshead Extension Rods And Diaphragm Stuffing Box Seals
With reference to Fig.4 remove the diaphragm stuffing box and plate (1) and rotate
pump so that crosshead is at the front of the stroke. Thoroughly clean the front of the
crosshead and the face of the crosshead extension rod. Insert alignment boss on crosshead
extension rod into the crosshead bore and tighten the retainer bolts (2) to the following
torque. Insert safety wire into the hole of bolt heads and tighten it.
ZYF-1300/1600 475～500N.m (350～370ft.lbs)
Thoroughly clean face of power frame and diaphragm stuffing box plate at position (A).
Install gasket (3) and capscrews (10). Tighten capscrews as follows:
ZYF-1300/1600 120～160N.m (90~120ft.lbs)

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 Fig.4
Clean bore and face of diaphragm stuffing box plate, Clean OD and flange of
diaphragm stuffing box. Coat OD of diaphragm stuffing box with light oil and install O-ring
seal (4). Insert diaphragm stuffing box in plate bore and tighten capscrews to the following
torque:
ZYF-1300/1600 16～24N.m (12～18ft.lbs)
The diaphragm stuffing box packing assembly consists of two double lip oil seal (6), a
oil seal ring (7), an O-ring (12)， O-ring (8) and a lock spring (9). Install the assembly as
follows:
a. Remove left pressure spring (5) from double lip oil seal (6) and place seal in the
inner ( power end) position on the crosshead extension rod, with lip toward power end.
Replace the pressure spring in the seal lip and slide the seal into position in the stuffing box.
SEE NOTE BELOW
b. Install the O-ring (12) into Oil Seal ring (7). Insert O-ring (12) and oil seal ring (7)
over rod and slide it into stuffing box bore.
c. Install the O-ring (8) in groove in stuffing box bore.
d. Remove right pressure spring (5) from double lip oil seal (6) and place seal in the
outer position on the crosshead extension rod with main lip toward power end, Replace the
pressure spring in the seal lip and slide the seal into position in the stuffing box.

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 SEE NOTE BELOW
* CAUTION：The double lip seal can be used in the inner or power end position to
replace the single lip seal, but DO NOT use the single lip seal in the outer position.
e. Install the lock spring (9).
* NOTE: CAUTION must be taken to assure the pressure spring (6) does not slip
out of the groove in the oil seal lip, as severe scoring of the crosshead extension rod can
occur. Coat extension rod with a light oil to facilitate installation of the packing
assembly.
7 Pistons And Liner Cooling System
Proper attention must be paid at all times to assure adequate cooling fluid is being
applied to the piston and liner assembly .Stoppage of the cooling fluid will result in almost
instant failure of the piston rubbers and possibly extensive damage to the liner bore.
Stationary spray type have been used on ZYF-series pumps, Ref. Fig 5. It consists of a
fixture (1), a pipe (2) and a spray nozzle (3), which applies cooling fluid in the form of a
spray to the piston and liner area. Adjust cooling water supply to the manifold so that a
spray approximately 305mm long is being discharged from each spray nozzle, Inspect spray
nozzle operation very often, making sure the nozzle is pointed directly at the piston.

Fig. 5
Cooling fluid be transfused from pump (Item 3. Fig.6) and Water tank (Item 5. Fig.6)
to the manifold on the frame . Adjust regulating valve (item 4 .Fig.6)to apply as much water
as possible to the liners without splashing back on the crosshead extension rods and
diaphragm stuffing box plate. 40L per minute per liner is the preferred flow rate, If water is
allowed to splash on the crosshead extension rods, some of the water will work back into

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the power end to contaminate the lubrication oil.

Fig. 6
The cooling fluid is returned from the crosshead extension rod compartment to the
setting chamber, and as the fluid overflows through the filter screen between the two
sections of the tank, the solids are allowed to settle out. The filter screen will catch much of
the foreign material floating in the fluid. With reference to Fig.7.

Fig. 7
Check condition of the cooling fluid at frequent intervals and CLEAN and FLUSH
reservoir as required. Contaminated fluid will cause premature liner and piston wear from
abrasion or stoppage of the spray nozzle or spray tube.
8 Assembly Of Fluid End Parts
With reference to Fig. 8
A cross-section through the fluid end for ZYF-1300/1600 is shown in Fig 8, clean and
assemble the fluid end parts in the following manner.

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 * Note: All of the parts in this fluid end assembly are designed with metal to metal
seating to alleviate friction wear from breathing action encountered in modern high
pressure pump operation. For this reason it is essential that all parts be clean and free
of rust, nicks and burrs before being assembled.
a. Liner
Install wear plate seal (1) in counter bore of fluid end. Slide wear plate (2) over studs
until it seats against fluid end. Slide liner thread ring (3) over studs with the starting thread
at the 5 o’clock position and tighten nuts to 640-690 N.m (470-5l0ft. lbs) torque.
ZYF-1300/1600 ASSEHBLY OF FLUID END PARTS

Fig.8
* Note: Placing the starting thread at 5 o’ clock position makes engaging the liner
lock threads much easier.
Place liner seal (4) in counter bore of wear plate(2).Apply thin coat of grease to ID of
liner lock (5) and slide over rear of liner (6). Install two-piece liner lock ring (7) in liner
groove and “o” ring to hold them in position. Slide liner handling tool over liner up against
liner lock ring and tighten set screw to secure it in place. Hoist liner assembly into position
with jib hoist.
Apply liberal coat of grease to liner lock threads, align the starting thread of the liner
lock (5) to the 7 o’clock position and insert the liner into the liner thread ring(3) , screw
liner lock in until liner seats in position. Tighten with sledge hammer on hammer lugs.
b. Piston Rod
Clean piston (9) and piston rod (8), making sure they are free of nicks and burrs, Install

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seal ring (10) in groove in piston head. Slide piston head (9) on rod while observing that
ring does not fall out of groove. Tighten piston rod nut (11) to 1625~2165 N.m
(1200~l600ft. lbs.)
Coat liner I.D. and piston O.D. with grease. Check ends of piston rod and extension rod
to be sure they are clean and free of burrs. Insert piston rod into liner through cylinder head
opening，holding piston rod centered at the rear of the liner. Drive the piston into the liner
with a driving tool or piece of hardwood and sledge hammer．Use caution as the piston rod
approaches the crosshead extension rod that the dowel on the end of the piston rod is not
damaged. The piston rod must be supported and the dowel guided into the pilot bore.
c. Piston Rod Clamps
The piston rod clamps are machined as one piece and then sawed in half. The two
pieces are stenciled with matching numbers on each half. The two pieces with the same
matching numbers should always be kept together as a set. Install the clamp around the rod
end flanges. Tighten cap screws to the following torque values:
ZYF-1300/1600 330 N.m (245ft. lbs)
When rods and rod clamps are new, a gap in excess of 5. 5mm could be present
between the two halves of the clamp. This is satisfactory provided the faces of the rods are
seating metal to metal. As wear occurs, the halves will pull closer together. Clamping action
will be lost when a gap no longer exists. At this time clamps must be replaced. Install splash
plate on rear of liner.
d. Lower Valve Guide and Cylinder Head
Insert the lower valve guide (13) through the alignment ring and position the guide
over the valve stem. Start the lock plate (14) and draw it down, compressing the valve
spring and seating the valve guide in the tapered slot .Install head seal (15) on cylinder head
plug (16). Coat seal and O.D. of plug with light oil.Slide it straight into the fluid end
opening. Apply a liberal coat of grease to the cylinder head threads and screw the cylinder
head (17) in against the plug (16). Tighten cylinder head with wrench provided and sledge
hammer.
Fluid leakage through the weep hole will indicate a defective seal or loose cylinder
head. DO NOT plug weep hole as this can result in severe damage to cylinder head threads,
thread rings, etc., in event of a liner seal failure.
e. Discharge Valve Pot Covers
Install discharge valve pot gasket (18) into bore, and after liberal application of grease
or tool joint compound to the gasket and thread area, tighten the discharge valve pot covers
into place, using a sledge hammer and bar.

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 f. Discharge Manifold all Models
A flange (51/8"-1500RTJ for ZYF-800/1000/1300/1600) connection is provided on the
discharge manifold. Remove flange and protect gasket area before welding (customer’ s
option) to the discharge piping. Tighten discharge flange connection bolts to 1625～
2165N.m (1200 ～ l600ft.lbs.) torque. To insure uniform make-up of the ring joint
connection, tighten flange bolt nuts in a cross-cross order. If a blind flange is installed on
the opposite end of the discharge manifold, check flange bolts and tighten to same
specification as noted above.
g. Suction Flange
The suction flange has a standard thread connection (10" NPT for ZYF-800, 12"NPT
for ZYF-1000/1300/1600) and is custom made to match the companion flange on the pump
suction manifold. An o-ring seal seals off the connection.
* Note: Thoroughly clean o-ring groove and face of flanges before making up
connection, Tighten flange bolts to 490~665 N.m.
h. Accessory Manifold
An accessory manifold Fig.9. is available for installation on the discharge manifold
opposite the discharge end, The manifold will accommodate a pulsation dampener (1)
(KB-75 for ZYF-1300\1600) and provides a 3" NPT and a ZG1-1/2" side outlet connections
for such items as a shear relief valve (3) and a pressure gauge (2) when manifold is used,
install and maintain as follows:
Thoroughly clean ring joint groove, install ring (4) and tighten the flange bolts (5) to
1625N.m torque. To assure uniform make-up of the ring joint connection, tighten the nuts in
a cross-cross order.

Fig.9
The shear relief valve (3) is installed on the discharge manifold for the purpose of

１８
protecting the pump from excessively high pressure overloads. The relief valve must be
installed so that it will be directly exposed to the mud. DO NOT PUT ANY TYPE OF
SHUT OFF VALVE between the relief valve and the manifold. Pipe the discharge side of
the relief valve directly into the mud pit with as few turns in the line as possible. IT IS NOT
RECOMMENDED for the discharge side of the valve to be piped into the suction line of the
pump.
The relief valve setting should be just above the maximum pressure rating of the
particular liner size being used. CHANGE SETTINGS with each liner size change, DO
NOT USE ALLEN WRENCHES, WELDING RODS, or material other than that called
for by the manufacturer of the relief valve, as this will affect the rating of the relief valve.
The mounting for KB-75 pulsation dampener (1) is a flange with R-39 ring gasket.
Before installing dampener, thoroughly clean ring groove and ring, and after setting
dampener into place, tighten the nut (8) to 1020 N.m torque, to insure uniform make-up,
tighten nuts in a cross-cross order.
Precharge dampener before starting up pump. Precharge pressure should not be more
than 2/3 of the pump discharge pressure or a maximum of 4.5MPa.
*CAUTION: Use only compressed nitrogen or air. Do not charge with oxygen.
9 Lubrication
Proper lubrication of the moving parts in any piece of machinery is the most important
single factor affecting its ultimate life. To obtain maximum trouble -free service life from
the power end of the pump, it is necessary to perform routine maintenance care and
inspections to insure the proper amount of CLEAN lubricant is being provided.
The ZYF-Series pumps utilize the controlled flow oil bath splash and pressure system
to lubricate the entire power end. The type of pressure system provided in each individual
pump will govern the minimum SPM at which the pump can be operated, i.e. pumps which
have pressure lubrication only to the main and pinion bearings, have a minimum rated speed
of 40 SPM. Pumps in which pressure lubrication is provided to the main, pinion, and
crosshead bearings and crosshead compartments may be operated at a minimum speed of 25
SPM, provided there is a minimum of 0.035MPa (5 PSI) oil pressure.
9.1 Minimum Operating Speeds
ZYF-Series pump have the total pressure lubrication system, and which can be
operated at 25 SPM (at pressure of 0. 035 MPa).
CAUTION: The pressure lubricating system can be provided with an externally
mounted oil pump driven through V-belts or internally mounted oil pump driven from
the main gear. When an internally mounted oil pump is used, the direction of rotation

１９
of the pinion shaft must be as shown in Fig.10.

GEAR PINION

OIL PUMP

Fig. 10
9.2 Controlled Flow Splash System
The controlled flow splash lubrication system is the same for all ZYF-Series pumps,
regardless of the type of oil pump drive provided for the pressure system. In the controlled
flow splash system, the main gear picks oil up from the reservoir, and when the teeth mesh
with the pinion, the oil is displaced into various troughs and compartments in the frame,
With reference to Figure 12, the oil thrown into trough (7) is directed through the oil tube (8)
to the two pinion bearings.
Oil passage from the top of the crosshead guide compartment to the crosshead bearing
is shown in Figure 11, Oil accumulates in the compartment over the crossheads. The oil
runs through the nipple (1) into the crosshead retainer to the oil passages (5) and on to the
crosshead pin bearing. As noted, the duplicate set of passageways (5) in the crosshead pin
permits the crosshead pins to be rotated without having to give attention to hole alignment.
This permits the installation of crosshead pins from either direction.

Fig. 11

9.3 Total Pressure Lubrication System

The total pressure lubrication system, incorporating the oil pump for the ZYF-series

２０
pumps, is shown in Figure 12.
In this system, filtered oil is supplied to the pump through the suction filter (1) and is
discharged from the pump into the manifold block (2). Oil is distributed from the manifold

Fig. 12
block to the pinion shaft bearing oil line (3) and spray nozzle (3A), and to the main bearing
oil line (4) and the crosshead compartment manifold block (4A) located above the crosshead
compartment. The crosshead compartment manifold block (4A) distributes oil to the
crosshead, crosshead bearings, and extension rods.
A pressure gauge (5) is mounted on the back wall of the frame to show oil pressure
being maintained in the manifold block. The oil pressure will be, of course, very
corresponding with the speed of the main pump, however if a sudden pressure drop or
increase occurs, refer to the section on maintenance of lubrication system for possible cause.
A pressure relief valve (6) is mounted to the manifold block (2) to keep excess pressure
from damaging oil pump and drive, The relief valve is preset at 0.27MPa (40 PSI) and must
not be tampered with.
When installing the internally mounted oil pump (9.Fig.12), position pump so that the
back face of the drive gear is flush and parallel with the edge of the main gear, and gear
teeth have 0. 60～0. 90mm backlash.
A typical layout for the pinion shaft driven oil pump is shown in Fig. 13. The oil pump
(1) is piped into the oil system through the suction and pressure connections on the bottom
inside wall of the power frame.
Ref. Fig. 13, adjust the V-belt drive (2) to a point where the two halves of the belt can

２１
almost be ‘pinched’ together between the thumb and fingers at the center of the drive. Over
tightening can cause premature failure of the pump. To prevent possible injury, always
install guard (3.Fig.13) over V-belts before putting pump into service.

Fig. 13
9.4 Maintenance of The Lubrication System
Adequate lubrication of the moving parts is, as stated, the most important single factor
affecting the ultimate service life of the pump, CARE AND MAINTENANCE of the system
is the sole responsibility of the operator or crew to which it has been assigned, and the
extent to which this is applied will determine the amount of trouble-free service life that will
be obtained.
The lubricant recommendations shown below , are the result of extensive field tests.
Substitutions should be made only in extreme emergencies.
Lubrication Specifications:
Use extreme pressure, non-corrosive, anti-foaming gear lubricant as follows:
Temperatures +30°F ～+155° F (-1℃～+68℃) AGMA No. 6#EP
Temperatures +0°F～+ 80° F (-18℃～+27℃) AGMA No. 4#EP
Temperatures -20°F～+ 40°F (-29℃～+4℃) AGMA No. 1# EP
OIL RESERVOIR CAPACITY:
ZYF-1300\1600 379 Liters(100 U.S.gal)
ONCE EACH TOUR, check and maintain oil level at the FULL mark on the bayonet
gauge. PUMP MUST BE SHUT DOWN and allowed to stand idle for approximately five
minutes to allow oil level to equalize.
ONCE EACH SIX MONTHS ,or more often if oil becomes contaminated with
abrasive particles or corrosive compounds, drain and flush the oil reservoir new lubricant.

２２
 Oil drains are located on either side of the pump frame.
During the flushing procedure, thoroughly clean the oil troughs and the compartment
in top of the crosshead guide.
Also clean or replace the filter element in the air breather cap and clean suction screen.
Remove covers from settling chamber and purge out contaminants before adding new oil.
Routine inspection on condition of oil should be made as condensation of moisture in
the air, intrusion of mud, water or dirt, can necessitate a more frequent oil change.
A settling chamber is located in the forward area of the power end floor,
Contamination in the oil splashed into this area is allowed to settle out and should be
drained out of the pump through the clean out covers located on the frame wall underneath
the crosshead inspection doors.
ONCE EACH MONTH, remove clean out covers on both sides of pump to drain
contaminated oil from settling chamber. Approximately 15-gallons of oil will be lost;
replenish the main reservoir to compensate for the amount drained out.
ONCE EACH WEEK, remove one of the lower 1/2″ capscrews that secure the clean
out cover to the frame to drain off water condensate.
ONCE EACH TOUR, check oil level in main reservoir. Maintain at full mark on
dipstick to the manifold block. If loss of pressure occurs, check for:
* Clogged suction screen
* Low oil level
* Slipping V-belt drive
* Broken or loose connections
* Damaged or worn oil pump
* Defective Relief valve
For an abnormal increase in oil pressure, check for:
* Plugged oil lines
* Contamination causing oil to be viscous
* Relief valve inoperative
* Defective gauge
* Other conditions
10 Maintenance
10.1 Power End
Routine inspection of the power end is the most important form of preventive
maintenance and will result in considerable savings by detecting any major trouble that
might be developing and allowing the necessary repairs to be made on a planned or normal

２３
rig-down time.
a. Check tightness of the main bearing bolts
Bolts must be tightened to the following torque:
ZYF-1300/1600 13210N.m(9750ft.lbs)
b. Safety wires
Check safety wires on all bolts including the main bearing hold-down bolts and
eccentric bearing retainer bolts, Replace any broken wires after retightening the bolts. Refer
to crankshaft assembly section for bolt torque requirements.
c. Oil lines
Check all oil lines to insure they are intact and free of obstructions. Check oil pump
suction hose for damage or flat areas.
d. Suction filter
Check condition of suction filter. Clean and replace as required.
e. Main bearing cover
Remove the main bearing cover and check tightness of main bearing retainer bolts,
condition of the bearing rollers, etc. Clean and remove any sludge or foreign substance that
might have accumulated at the bottom of the bearing area.
f. Main gear and pinion teeth
Inspect the condition of the main gear teeth and pinion gear teeth for any indications of
abnormal wear.
During the initial break-in period there will be some pitting on the face of the gear
teeth. This is referred to as "initial pitting" and is not harmful to the life of the gear.
However, if routine inspection indicates the degree of pitting continues to increase,
immediately contact the pump manufacturer for a more thorough inspection of the gear.
g. Crosshead pin bolts and crosshead guides
Remove cover and check condition of the crosshead pin bolts and safety wires. (Center
crosshead pin bolts can be reached by removing back cover and placing eccentric on outer
top dead center.) Tighten crosshead bolts (Item 4 Fig. 18) to the following torque:
ZYF-1300/1600 225～240 N.m (165～l75ft. lbs)
DO NOT EXCEED THESE VALUES. USE TORQUE WRENCH.
If the crosshead or guide shows abnormal wear or scoring, replace immediately as the
metal particles can cause damage to the bearings, etc. Excess wear can also cause rapid
wear to the piston and liner.
h. Oil and oil reservoir
Check condition of the oil and cleanliness of the oil reservoir. Service oil system as

２４
described in the Lubrication Section of this manual.
i. Roller bearings
Although the basic construction of the various sizes of ZYF-series pumps varies
somewhat, they all have one very important detail in common roller bearings. A roller
bearing is a precisely built machine within itself; therefore, careful handling is required in
order to obtain the long service life and high load carrying characteristics associated with
anti-frication bearings.
The main bearings are self-aligning spherical roller bearings. The pinion shaft is
mounted on straight roller bearings. The eccentric bearings are straight roller with thrust
plates on each side to keep the eccentric straps in line, and the crosshead pin bearings are
straight needle roller bearings.
None of the bearings require special adjustments. All inner and outer races are
assembled by means of very accurate fits. This accuracy is necessary; therefore, if the
bearings are to be used again, the inner and outer races and the roller assemblies of each
bearing must be kept together, and reinstalled exactly as they came off. It is always
necessary to completely replace any roller bearing that fails, even though only one part of
the bearing shows damage. Since the running clearances of these bearings are extremely
small, excessive clearances, worn or grooved raceways, and any pitting or flaking of the
parts is indicative of failure and the entire bearing should be changed as soon as possible.
All roller bearings are assembled to their shafts by means of shrink fits. (Ref. bearing
fit data under each shaft assembly,) Damaged or worn bearings and raceways can be
removed by driving them off the shaft with a bar and hammer. They can be cut off the shaft
with a burning torch, but care must be taken not to burn into the shaft. Bearings should
always be heated in an oil bath, the temperature of which should not exceed 149℃ (300°F).
Be certain that both the oil and the container are very clean. If the oil container is in direct
contact with the fire, place a rack into the container so that the bearings will not rest on the
bottom. Do not leave the bearings in the oil bath longer than three minutes.
Do not heat the bearings with a torch unless it is the only possible means available.
When it is necessary to use a torch, it should be used only by an experienced welder or
mechanic. Hold the torch at least l50mm (6 inches) away from the bearing and keep the
torch moving at all times. Heat the bearing only until it is hot to the touch. Use a tempil
stick. DO NOT OVERHEAT THE BEARING. Overheating draws the temper of the metal
and makes the bearing soft.
Once the heated bearing is in place on the shaft, hold it in place until it cools. NEVER
USE WATER OR ANY OTHER LIQUID TO COOL A HOT BEARING. Rapid

２５
cooling will cause the surfaces of the races and rollers to "check" or crack and the bearing
will fail immediately.
Never strike a roller bearing with a steel hammer, If the bearing must be driven into
position, use wood or a soft hammer and strike lightly.
Always lubricate the shaft or housing before installing the bearing. Clean white lead, or
an anti-seize compound, is the best lubricant for this purpose.
Do not remove a new bearing from the box or wrapping until it is to be installed.
Protect it from dirt and other foreign matter at all times. If a bearing must be cleaned, use
clean kerosene or other solvent.
10.2 Pinion Shaft Assembly

Fig.14
Chart Ⅱ ZYF-1300/1600 Pinion Shaft Bearing Fits
Description Position mm Inches
Inner Race to Shaft A T0.050~T0.109 T 0. 002～ T0. 0043
Outer Race to Bore B L0.115~L0.018 L0. 0046～L.0. 0007
Carrier to Frame Bore C L0.203~L0.076 L 0.008～L0.003
The pinion is an integral part of the shaft leaving only the installation of the bearings
and oil seal Spacer to complete the assembly.
The running clearances of the bearings are predetermined by their precision fit to the
shaft and the bearing carrier. When performing maintenance or overhaul, make sure the fits
shown in chart Ⅱ are obtained.
When installing the pinion shaft assembly in the pump observe the following
precautions:
a. Insure pinion bearing carrier gasket (1) and oil seal carrier gasket (2) are in place
and in good condition.
b. When installing the pinion bearing carrier (3) and the oil seal carrier (4), MAKE

２６
SURE THE CARRIERS ARE INSTALLED WITH DRAIN HOLES AT THE TOP to
correctly position oil troughs and align drain holes.
c. Remove burrs, dents or gouges from the OD of the oil seal spacer (5) before sliding
oil seal carrier (4) into place. Exercise care when sliding lip of seal over end of shaft to
prevent it from being damaged by the sharp edge of the keyway. Also pay particular
attention to insure oil seal lip IS NOT TURNED UNDER by edge of spacer when sliding
seal onto the spacer.
d. Tighten pinion bearing carrier bolts (6) to the approximate torque shown below:
ZYF-1300/1600 190~225 N.m (140~165ft.lbs)
e. Check condition of the pinion bearing inner and outer race and rollers. If there is any
indication galling of flaking or grooving, or if diametric clearance exceeds 0.2～0.25mm, it
is recommended the entire bearing be replaced.
10.3 Crankshaft Assembly (Fig. 15)
The crankshaft assembly consists of the crankshaft, eccentric ring gear, eccentric strap
with bearings, and the main bearings.
The running clearances of the bearings are predetermined by their precision fit to the
shaft and their respective bores. When performing any maintenance or overhaul, make sure
the fit shown in chart Ⅲ are obtained.
Assemble the crankshaft in the following manner: (Refer to Fig. 15)

Fig.15

２７
 ChartⅢ ZYF-1300/1600Crankshaft Assembly Bearings Fits

Description Position mm Inches

Inner Race to Shaft A T 0.056～T 0.103 T 0.0022～T 0.0041

Outer Race to Bore B(L) L 0.108～L0 L0.0042～L 0

Outer Race to Bore B(R) L 0.2～L 0.128 L 0.0079～L 0.005

Inner Race to Shaft C T 0.175～T 0.300 T 0.0069T～T 0.0118

Outer Race to Bore D T0.102～L 0.049 T0.004～L 0.0019

Gear to Flange E T 0.026～T 0.216 T 0.001～T 0.0085

Carrier to Frame Bore F L 0.050～T 0.050 L 0.002～T 0.002

Outer Race to, Bore G T 0.016～T 0.076 T 0.0006～T 0.003

Inner Race. to Pin H T 0.031～T 0. 091 T 0.0012～T 0.0036

a. Mount gear on flange.
Thoroughly clean mating faces of ring gear and flange, and bolt flange into position.
Tighten flange bolts (2) to the following torque:
ZYF- 1300/1600 2455N.m (1810ft. lbs)
Set crankshaft on a set of rollers (at main bearing position) and check run out on face
of gear witha dial indicator. If total indicator run out exceeds 0.l5mm, remove gear and
determine cause of misalignment.
NOTE: If run out on face of gear is checked while crankshaft is mounted in the
pump frame, the running clearance in main bearings will require that a simultaneous
set of dial indicator readings be taken at the end of the shaft and the face of the gear;
the actual face run out at any point being the difference between these readings.
b. Install the outer races of the eccentric bearings (13) and the outer race retainer ring
(3)in the three eccentric straps. Outer race retainer ring must be positioned so that oil scoop
is at the bottom when pump is at mid-stroke. Tighten retainer bolts (4) to the following
torque and tighten safety wire heads.
ZYF- 1300/1600 60～90N.m(44~66ft.lbs)
NOTE:The inner and outer races of the eccentric bearings are matched and must
not be intermixed.
c. Install the outer race of the crosshead bearings (19) in the three eccentric straps. It is
preferred that the outer race assembly be ‘pressed’ into position of frozen in “dry ice” or a

２８
deep freeze until it can be inserted into the bore. Under emergency circumstances, using a
large torch and heating the eye of the eccentric strap can install the outer race assembly. DO
NOT EXCEED 149℃ (300°F) (Use Tempil-Stick) and DO NOT USE WATER to cool the
strap.
NOTE: The inner and outer races of the crosshead bearings are matched and
should not be intermixed.
d. Install the inner race of the crosshead bearing on the crosshead pin and mark
according to their respective eccentric strap positions, Remove all nicks and burrs before
shrinking race into place. Refer to bearing fit position H in Chart Ⅲ.
e. Install inner race of the center eccentric bearing on the shaft. slide center strap into
position and install inner race clamp (5). Tighten socket head screws (20) in clamp to the
following torque:
ZYF-1300/1600 60～90N.m(44～66ft.lbs)
f. Install snap ring (7) in the groove on RH eccentric and shrink inner race of eccentric
bearing on shaft. After sliding the RH eccentric strap into position, install inner bearing
retainer (14).
Tighten inner race retainer bolts (8) to the following torque:
ZYF-1300/1600 60～90N.m(44～66ft.lbs)
g. Install the LH eccentric bearing ring (other than snap ring) and eccentric strap under
the same procedure outlined in step (f) above.
h. Place main bearings (9) in the main bearing carriers (10 LH and 11 RH) and install
outer race retainer (12) and retainer bolts (15) . Tighten bolts to the following torque:
ZYF-1300/1600 60～90N.m(44～66ft.lbs)
*NOTE: Even though the main bearing carriers (10 LH and 11 RH) have
different configurations on the OD, they are interchangeable and will fit into the pump
frame on either side, The purpose of the shoulders on the OD of one of the carriers is
to locate and retain the crankshaft in its respective position in the frame.
i. After installing the two main bearing spacers (16), shrink main bearings (9) on each
end of the shaft. Install inner race retainers (17) and retainer bolts (18). Tighten retainer
bolts to the following torque:
ZYF-1300/1600 60～90N.m(44～66ft.lbs)
j. Installing crankshaft assembly in frame.
In order to obtain a more precise fit between the main bearing housing and the frame bore
on ZYF-Series pumps, the installation procedures outlined below are to be followed (Refer
to Fig. 16).

２９
 1. Place piece of wood between eye of eccentric strap and crosshead guide (as shown
in Fig. 17) to protect guide from scoring or gouging as the straps are sliding into position.
2. Rotate the main bearing carrier so that the two flat spots (180°apart) are parallel
with the main bearing bolt holes, and slowly lower the crankshaft into position. (The flat
spot provides clearance for the main bearing bolts.)
Torque to Value Shown in Chart

Lead Wire
or

0.50mm Shims
(0.020″)

Fig.16
3. After placing crankshaft in the frame, and before installing the main bearing caps,
check the rollers in the main bearings to assure that each row of rollers in each bearing is
equally loaded. Equal loading is obtained by positioning the floating bearing carrier so that
the same number of inner and outer rollers supporting the weight of the crankshaft in each
bearing are tight. Because of tolerances, etc., the total number of tight rollers could be very
slightly different between individual bearings.
4. Install and shim main bearing caps to obtain 0. 10mm (0.004" )clamp or preload on
the main bearing carrier. This preload is obtained by placing the correct amount of shims
under the main bearing cap. The required amount of shims is determined as follows: (Fig.
16)
a. Install 0. 50mm (0. 02" )shims under both ends of the main bearing cap.
b. Place a piece of lead wire (approximately 0.8mm diameter) or plastigage between
OD of bearing carrier and ID of bearing cap, as near center of bearing cap as can be
determined, and tighten main bearing cap bolts to torque values shown in Chart Ⅳ.
c. Remove main bearing cap and determine clearance between bore of cap and OD of
bearing carrier by either mikeing thickness of lead or measuring compressed dimension of
plastigage.
d. Using this dimension, calculate the required thickness of shims as follows:

３０
 Subtract thickness of compressed lead or plastigage from the original 0.5mm shim
thickness. Then subtract 0.1mm for preload.
The result is the correct shim thickness required.
Example:
0.50 mm Original shims 0.020"
Less 0. 13 mm Lead Thickness Less 0.005"
0.37 mm 0.015"
Less 0.10 mm Clamp Fit Less 0.004"
0.27mm Correct Shim Thickness 0.011"
* NOTE: Machining tolerances make it necessary to determine individual shim
requirements for each (right hand and left hand) main bearing cap.
e. Install main bearing caps with the correct amount of shims as determined above, and
tighten main bearing bolts to torque values shown in Chart Ⅳ.
f. Again check inner and outer row of rollers on each bearing as previously outlined to
assure equal loading is still present on each bearing.
Chart Ⅳ
Torque Wrench Size
Thread Size
N.m ft.lbs mm in
ZYF-1300/1600 13210 9750 3″-8UN 92.0 3-5/8″

10.4 Installation of Crosshead Guides

When installing crosshead guides observe the following procedures and precautions：
a. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from
both sides of the guides and the frame bore where the guides fit.
b. If old guides are to be reused, inspect the wearing surfaces for wear and scoring
streaks.
* NOTE: For ZYF-1300 and ZYF-1600, upper and lower crosshead guides are
NOT interchangeable. In these pumps, the guides are machined so that the lower guide
places the crosshead on frame centerline, and upper guides are machined to afford
proper crosshead to guide clearance.
c. Install upper and lower guides, Torque guide screws to 200~270N.m (150~200ft.
lbs).
d. Check between frame and guide at points A, Fig.18, with 0.05mm (0.002") feeler
gauge to make sure guides fit into frame bore.
10.5 Installation of Crossheads

３１
 The crossheads in the pumps can be installed through the front (fluid end) or back end
of the crosshead guide. Reference Fig.17. When installing crossheads, observe the following
precautions:

a. Thoroughly clean all dirt or contamination and remove all burrs or rough edges from
OD of the crosshead, crosshead pin bores, and inner bore of crosshead guide. Dry crosshead
pin bore so that taper bore connection will make up metal to metal. See Note.
b. Position "eye" of eccentric strap at the opening in the side of the crosshead guide.
Block eccentric strap so that crosshead will clear the "eye" as it is sliding into position to
where the crosshead pin holes are in alignment. Ref. Fig 17.
c. Install the left hand crosshead first, rotate eccentric assembly to move "eye" into
center crosshead and right hand eccentric strap "eye" back, affording clearance to install
center pin through right hand crosshead inspection door. Remove diaphragm stuffing box
plate (1, Fig.18) and install right hand crosshead through this bore. Slide into place and
install crosshead pin.

Fig. 18 Fig. 18A

３２
 d. Install crosshead pin retainer (2) and retainer bolts (3) and rotate pin until the four
crosshead retainer to crosshead bolt holes (4) are in alignment. Install the crosshead
retainer to crosshead bolts and make up hand tight. Ref. Fig 18. 18A .
Referring back to fig.11, crosshead pin (4) can be installed without regard to oil holes
(5). Two holes are provided so the pin can be rotated 180°in relation to pin to retainer plate
screws (3).
Seat crosshead pin in taper bore by bumping large end with a light blow. Tighten
retainer bolts (3 and 4, Fig.18) to the following torque and safety wire:
ZYF-1300/1600 225~240N.m (165~175ft. lbs)
DO NOT EXCEED THESE VALUES. USE TORQUE WRENCH.
*NOTE: To pull the crosshead pin, remove the four crosshead retainer to
crosshead bolts (4) and screw two of the bolts into the “jack screw” holes (5). Tighten
the two jack screw bolts until the pin breaks loose. Complete removal of the crosshead
pin retainer plate (2) and slide pin out of bore.
e. Check running clearance of crosshead by sliding long “feeler” gauges between top of
crosshead and crosshead guide bore. The clearance should not be less than 0.508mm
(0.020"). Check with long feeler gauge over entire surface of crosshead.
* NOTE: Less running clearance at center of crosshead can be caused by swelling
from overtightening the crosshead pin retainer bolts (4). If present, loosen pin and
retighten into place by using the make-up torques shown below：
ZYF-1300/1600 225~240N.m (165~175ft. lbs)
* NOTE: If old crossheads are to be reused, inspect the sliding surfaces for wear
or scoring. If necessary, the crosshead may be switched to opposite sides of the pump
and rotated 180°to provide a smooth surface for the bottom of the crosshead. The
center crosshead can be rotated 180° and the crosshead pin installed from the opposite
side of pump.
10.6 Checking Crosshead Alignment
In order for the pistons to run true in the liners, the crosshead must travel in a straight
line along the horizontal centerline of the frame bore. To check and adjust crosshead
alignment, proceed as follows:
a. Remove diaphragm stuffing box from the diaphragm plate, (Fig. 18).Do not remove
the plate.
b. Position crosshead at the extreme front of its stroke, with inside calipers or
telescoping gauges, accurately measure the distance from the diaphragm plate bore to the

３３
crosshead extension rod at the top and bottom. Compare the two measurements to determine
the position of the rod relative to the centerline of the bore.
c. Rotate pumps to extreme rear of stroke and take measurement again at the same
place. Compare these measurements to the ones taken at the front of the stroke to determine
if crosshead is running horizontal.
d. If the centerline of the extension rod is more than 0.381mm (0. 015″) low in the
diaphragm plate bore, shims should be inserted under the lower guide to bring the extension
rod back to center, provided there is ample clearance between the top of crosshead and
upper crosshead guide. It is normal for the lower guide to wear more at the rear due to
heavier loading at this point because of the angle of the eccentric strap. It is permissible to
shim the guides on a taper if it is done accurately to provide firm support for the guide. Do
not shim guides to less than 0.50mm (0.020" )clearances ，large crosshead clearances are
acceptable due to characteristics of triplex pump operation, the crosshead pressure is always
on the lower guide.
*NOTE: For the driving reason，when the pump must be reverse rotating，thus
the crosshead pressure is on the upper guide，so crosshead clearances must be
controlled in 0.45~0.55mm（0.0177″~0.0217″）.
e. Cut shims from steel shim stock long enough to reach completely across the guides.
Cut tabs on the side to bend down over frame supports to hold them in place. Refer to items
c and d under Installation of Crosshead Guides.
10.7 Fluid End Maintenance
For many years, the fluid end of a pump was considered a non-wearing part which did
not cause any concern other than possible infrequent repairs or replacements resulting from
fluid cuts or washouts. However, the higher pressures of the present-day drilling
requirements have resulted in higher stresses being imposed on the fluid end which, when
combined with the corrosive characteristics of the drilling fluid, have resulted in the demand
that more and better maintenance be given to the fluid end parts and pieces if a reasonable
operating life is to be obtained. A few of the obvious points are as follows:
a. Make sure all valves on the discharge side of pump are opened before pump is put
into operation. Kicking pump in against a closed valve can often be the start of a fatigue
crack. An open crack may not necessarily occur at the precise moment, however a small
crack could occur and start the process of “corrosion fatigue failure”.
b. Do not engage pump clutch when prime mover is running at a high rate of speed. To
do so can cause undesirable shock loads against both power end and fluid end.
c. Properly maintain pressure relief valve to assure it is set for the pressure rating on

３４
the liner size being used.
d. Do not operate the pump for an extended period of time if a severe fluid knock is
present.
e. Properly prepare fluid end for storage. When pump is to be shut down or not
operated for a period of ten days or more, it is recommended that the fluid end parts such as
liners, pistons, rods, etc., be removed from the pump and the fluid end flushed out
completely with fresh water, After a thorough flushing, apply grease or a rust preventative
to all of the machined surfaces such as valve pot cover threads, valve pot cover gasket
surfaces, valve seats, liner bores, etc. the parts removed from the pump including liners,
piston rods, etc., should of course be protected from the elements. This will not only extend
the life of the fluid end through resistance to corrosion, but will also protect the usable life
still left in the expendable parts and maintain them in good condition for installation in the
pump at the next start-up period.
Maintenance and repairs should be made on the fluid end assembly by observing the
following precautions. Refer to figure 19.
The fluid end assembly for these triplex pumps consists of three-forged cylinder blocks,
complete with valve pot covers and cylinder heads, a suction manifold, and a discharge
manifold.
①Fluid Cylinder Blocks
The three separate fluid cylinder blocks (1) bolt metal-to-metal to the power end frame
through retainer studs (2). Alignment with the power end frame bores is obtained through
the “pilot” boss on fluid end. However, to obtain accurate alignment, all nicks or burrs must
be removed from pilot boss and frame bore and all dirt and foreign matter cleaned from the
mating surfaces; otherwise cylinder blocks could make up in a cocked or misaligned
position.
The fit between pilot boss and frame bore position (D) is as follows:
Pilot Boss（for ZYF-1300/1600 pump，the wear plate forms the pilot boss） to Frame
L0.13mm～L0.28mm(L0.005"～L0.011"), Install the three cylinder block nuts to the torque
values shown in Chart V.
②Suction Manifold
The suction manifold (3) bolts to each cylinder block and is sealed through the O-ring
in the connection flange. Thoroughly clean O-ring groove, the O-ring sealing surface on
bottom of the cylinder block, and replace O- ring seal before bolting manifold into position.
The flange connection MUST make up metal-to-metal to retain the O-ring seal, therefore
any nicks, grooves or washouts on the sealing surface must be repaired before installation.

３５
Ref. Welding and Repair Section in this manual for repair procedures.
Start all suction manifold bolts (5) in the three cylinder blocks before tightening.
Tighten to torque values shown in Chart V.
③Discharge Manifold
The discharge manifold bolts to each cylinder block and is sealed through the O- ring
in the connection flange.
Thoroughly clean the O-ring groove, the O-ring sealing surface on face of the cylinder
block before bolting the manifold back into position. The flange connection MUST make up
metal-to-metal to retain the O-ring seal, therefore any nicks, grooves, or washouts on this
sealing surface must be repaired before installation. Ref. Welding and Repair Section in this
manual for repair procedures.
Start all discharge manifold bolts (8) in the three cylinder blocks before tightening.
Tighten to torque values shown in Chart V. Tighten cylinder block to power frame stud nuts
to torque values shown in Chart V.
④Cylinder Head Thread Ring
A replaceable cylinder head thread ring (9) is bolted on to the face of the cylinder
blocks. The thread ring must make up metal-to-metal with face of cylinder blocks in order
for the axis of the threads to be perfectly square with the cylinder block bore. Therefore,
make sure all burrs, extrusions, or foreign matter is removed from the mating faces before
making installation.
* NOTE: Install thread ring so that the “bleed hole”is in the down position. Tighten the
cylinder head thread ring stud nuts (10) to the torque values shown in Chart V.
Chart V
TORQUE
POSITION ITEM
N.m ft. lbs
Cyl. Block to Power End ZYF－1300/1600 2 2170 1600

Suction Manifold ZYF－1300/1600 5 325 240

Discharge Manifold ZYF－1300/1600 8 1355 1000

Thread Ring ZYF－1300/1600 10 2170 1600

３６
 Fig.19
Chart Ⅵ
ZYF-1300/1600
Position
mm in
A 209.55-209. 68 8.250-8.255
B 180.97-181.10 7.125-7. 130
C 209.60-209. 68 8.252-8.255
D 368.275-368.325 14.499-14. 501
E 6.35 × 45° 1/4″ × 45°
F 76.07-76. 20 2.995-3.000
G 15.75-15.85 0.620-0.622
H 28.50-28. 70 1.122-1.130
J 149.10-149. 30 5.870-5.878
K 158.67-158.81 6.247-6.252
L 168.53-168.66 6.635-6.640
M 187. 33-187. 46 7. 375-7. 380
N 12.60-12.80 0.496-0.504
P 1 ：6 2"taper per ft.on dia
10.8 Welding and Repairs

３７
 On occasion where washouts or normal wear cause repairs to be made to the fluid end
bores, the following welding procedures and precautions should be closely followed.
Machine bore all dimensions to those shown in applicable chart VI, and in all cases
maintain the shoulders (where liners, covers, seat, etc.) 90° to the axis of the bore.
Welding Procedures：
* NOTE: Weld repairs can usually be separated into two categories:
① Washouts, and ②Cracks. Listed below is the basis information for the repairs:
a. Washouts:
☆ Weld as 30 carbon Steel.
☆ Clean area by grinding or Arc-air.
☆ Before starting any welding procedure, make sure the electrodes are dry of moisture,
and if necessary, put in oven and bring up to temperature required to drive out moisture.
☆ Spot heat area to 250°F～350°F(120℃～180℃)out in all directions for a minimum
of 75mm(3″).
☆ Use AWS-ASTM E-60-7018 low hydrogen rods, Example-Adam-Arc 7018.
☆ Temperatures should be brought back to 250°F～350°F(120℃～180℃) after each
pass and maintained throughout the welding. After welding is completed and area cleaned,
heat to 250°F～350°F(120℃～180℃) and allow to cool.
b. Cracks
Grind out all of crack. Any attempt to burn out a crack will only result in the crack
progressing faster than the material can be burned.
Follow the same welding procedure as above.
c. Preheating
The purpose of preheating is to expand the area being repaired so that as the cooling
process takes place, the welded area and the preheated area will cool more uniformly.
Preheating also prevents hard spots from forming between the base metal and the welding
by eliminating a thermal shock as the weld is being applied. This hard spot will, of course,
be a good place for fatigue cracks to occur.
10.9 Repairs to Valve Pot Cover Bore
When making repairs to washouts in the valve pot cover bore, it is extremely important
that the surface where the valve covers seats is either "machined" or "ground" perfectly flat
and 90° to the axis of the threads. As shown in Fig. 20, the valve pot cover gasket (1) seats
into the counter bore at top of valve cover deck, and as the cover makes up metal to metal to
the valve deck, the gasket is confined within its counter bore .Obviously, any high spots on
the valve cover deck from weld repairs, or any low spot from over- grinding of the repairs

３８
can result in a gap between top of the valve cover deck and bottom of the valve cover,
through which the valve cover gasket can be extruded under pressure.
The high or low spot can also cause valve covers to make up in a "cocked" position
and result in severe thread damage (cracks) due to the axis of the two mating threads being
out of square.

Fig.20
10.10 Operating Maintenance
Proper maintenance of the pump in time is the necessary measure to assure the pump
working and prolong the service life. For using any pump, maintenance should be paid more
attention to.
10.10.1.Daily Maintenance
1) After stopping the pump, check the oil level of power end, at least once a day. If
chain drive is used, the oil level of chain box should be checked.
2) Check the working situation of the liner and piston, it is normal that a little mud is
taken out with piston. If there is leakage, the piston should be changed. Check the abrasion
of liner inner bore, if the abrasion is severe ,the liner should be changed in time.
3) Check the liner compartments of the frame. The mud and contamination should be
cleaned.
4) Check the water tank of spray pump. The water or oil should be supplied if there is
not enough. The polluted water should be changed and the water tank should be cleaned.
5) Check if the pressure of discharge pulsation dampener meets the requirements.
6) Check the reliability of relief valves, if necessary, they should be changed.
7) Check the lubricating oil pump for the variation of pressure gauge, if the pressure
is very low (lower than 0.035MPa) or no pressure, check if the suction and discharging filter
screen are plugged.
8) Loose the coupling of piston rod every day, check if the pyramidal face of

３９
coupling and the junction face of piston rod and extension rod are clean, rotate the piston
rod a quarter round and tighten. The purpose of doing that is to make the wearing face
evenly and prolong the service life of liner and piston.
9) Before tightening the valve cover, the lubricating grease should be coated on the
threads and be checked once four hours for loosing.
10) Check the alarm bore of valve cover seal and liner seal (including the seal between
wearing plate and cylinder), if the mud discharges, the relative seal ring should be changed.
10.10.2Weekly Maintenance
1) Disassemble the valve cover and clean them every week, meanwhile coat the
molybdenum disulfide complex calcium base grease. Check the inner sleeve of valve guide,
if there is sharp abrasion (that means the clearance between the valve guide pole and guide
exceeded 3mm), it should be changed to avoid the guide failing to guide the valve motion in
the right way and accelerating the abrasion of valve.
2) Check the valve and valve seat, change the worn or pierced valve body, valve
rubber and valve seat (when changing the valve seat, the valve body should be changed at
the same time).
3) Check the locknuts of the piston. The corrosive or damaged locknuts should be
changed (The seal rings in the locknuts will fail after the locknuts are tightened three times).
4) Drain water one time from the plug of drain flange until oil comes out.
5) Check and clean the filter screen in the lubricating oil line.
10.10.3 Monthly Maintenance
1) Check all the stud bolts and nuts of fluid end. For example: nuts among cylinders,
nuts connecting the cylinder to frame, the bolts and nuts on the suction and discharge
manifold. If they are loose, they should be tightened to the specified torque valve.
2) Check the seal rings in the packing box of extension rod. The worn one should be
changed. Usually, change it at least once every three months. Attention should be taken to
the oil seal position when changing (the lip should be inward).
3) Remove and clean the filter installed in the discharge manifold.
Change the dirty oil in the oil pool of power end and the oil groove of crosshead every
six months. Clean these oil grooves at the same time.
10.10.4 Yearly Maintenance
1) Check if the crosshead guide is loose, if the crosshead running clearance conforms
to requirements, the clearance can be adjusted by adding shim under the guide rotating the crosshead
180°.
2) Check the whole pump completely every two years or three years, check if the

４０
main bearing, connecting rod bearing, crosshead bearing, input shaft are worn or outworn.
They should be changed if they cannot be used any more.
3) Check the wear of gears, if they are worn sharply, the drive shaft and the driven
shaft should be turnaround installed to use the face that is not worn.
For the convenience of maintenance, check points are listed in chartⅦ and Fig.21.
10.10.5 Cares should be taken for the following in maintenance.
Before tightening the coupling connecting the extension rod and piston rod, the
25°taper face should be cleaned.
When changing the liner, the liner seal ring should be changed as well.
After stopping the pump in winter, the mud in the valve compartment and liner should
be discharged and cleaned completely.
Cover each inspection hole to avoid the sand dropping into the lubricating oil.
The discharged pulsation dampener is only allowed to charge inert gas (such as
nitrogen) or air. No inflammable and explosive gases are allowed such as oxygen，hydrogen
etc..

CHART Ⅶ Maintenance List

Interval No. Maintenance
Check the oil level after stopping the pump, if it is too low, it should be
Daily 1
added to required level.
Check if the readings of pressure gauge of lubricating oil pump are
Daily 2
normal. when the pressure is too low, the cause should be found at once.
Daily 3 Check if the dampener works normally.
Fill the cooling lubricant up to the spray pump water tank when it is not
Daily 4
enough. Change it when it deteriorates.
Daily 5 Check the liner compartments. Clean it when necessary.
Check if the cylinder heads are loose every four hours. Coat lubricant on
Daily 6
the thread when tightening.
Daily 7 Check if the piston and liner seal leaks, change them when necessary.
Loose the coupling of piston rod one time daily, rotate the piston rod a
Daily 8
quarter turn and then tighten the coupling back again.
Check if the valve bonnets are loose every four hours. Coat lubricant on
Daily 9
the thread when tightening.
Daily 10 Check if the safety valves are reliable.

４１
Interval No. Maintenance
Check if the pre-charging pressure of discharge pulsation dampener is
Daily 11
normal when stopping the pump.
Observe the alarm bore, if the mud is discharged, the related seal ring should be
Daily 12
changed.
Disassemble the cylinder heads pulg and clean it, coat it with
Weekly 13
molybdenum disulfide complex calcium base grease.
Check the inner sleeve of valve guide, if it is worn, it should be
Weekly 14
changed.
Check the suction and discharge valve body, valve seat and valve
Weekly 15
rubber, change the damaged one.
Check if the locknuts of piston are corrosive or damaged. Change if they
Weekly 16
are damaged (normally, change after using three times).
Weekly 17 Check the filter screen of lubricating system. Clean it if it is plugged.
Loosen the plug of drain flange, discharge the dirt and water in the oil
Weekly 18
pool.
Check the bolts of fluid end, the loose or damaged bolts should be
Monthly 19
tightened or changed.
Check the seal ring in the packing box, the worn one should be changed
Monthly 20
at least once every three months.
Monthly 21 Check the filter in the discharge pipe. Clean it if it is plugged.
Change the dirty oil in the oil pool of power end and crosshead oil
Monthly 22
groove and clean them every six months.
Check the wear of crosshead, if necessary, use the crosshead after rotating
Yearly 23
180°。
Check if the guide is loose, check if the crosshead clearance conforms to
Yearly 24
requirements, otherwise, they should be adjusted.
Check the wear of tooth face of the pinion and the gear, if necessary,
Yearly 25
use them reverse face.
Check if the pinion shaft and crankshaft are all right. Measures should
Yearly 26
be taken if there are abnormal phenomena.
Yearly 27 Check the bearing of power end. The damaged one should be changed.
Check the seal of rear cover and crank shaft end cover, if the seal is not
Yearly 28
good, it should be changed.

４２
 Fig.21
10.11 Troubleshooting
During the running of the pump, if there are troubles, the reason should be checked and
the trouble should be solved, otherwise, they will affect the normal working of the pump.
10.11.1 Trouble of Fluid End

Trouble Cause Troubleshooting

1.The pressure readings 1.The charging piping is not 1.Tighten the flange bolts of
become low and the sealed off and the air gets into charging piping or change the
discharge reduces or no the pump. gasket.
mud discharged. 2.The suction filter screen is 2.Stop the pump and clean the
plugged . suction filter screen.
2.Uneven discharge. The 1.A piston of a valve is worn 1.Change the damaged piston and check
pressure gauge fluctuates. out or damaged . the valve to find if it’s damaged or
The charging piping has 2.There is air in the pump plugged .
abnormal noise. cylinder. 2. Check if the charging piping
and valve cap are sealed off.

４３
 Trouble Cause Troubleshooting

3.There is severe slap in 1.The piston nuts are loose . 1.Tighten the piston nuts.
the line . 2.The liner cover is loose. 2.Tighten the liner cover.
3.The suction is not good 3.Check the reason of improper
caused water dash. suction .
4.The mud leakage from 1.The valve cap is not 1.Tighten the valve cap .
the alarm bore of valve tightened . 2. Change the seal ring .
cap, cylinder and liner 2.The seal ring is damaged .
seal.
5.The discharge pulsation 1.The charging connector is 1.Clean the connector .
dampener can’t be plugged . 2.Change the bladder .
charged or it leaks after 2.The bladder of the pulsation 3.Repair or change the needle
charging . dampener is broken . valve .
3.The needle valve is not
sealed .
6.The diesel is verloaded . The discharge filter drum is Remove the filter screen and
plugged. clean it.
10.11.2 Trouble of Power End

Trouble Cause Troubleshooting

1. Overheat of bearing 1.The oil pipe or port is 1.Clean the oil pipe or oil port.
plugged. 2.Change oil.
2.The lubricating oil is too 3.Repair or change bearing.
dirty or deteriorated. 4.Add proper amount of oil.
3.The rolling bearing is worn
or damaged.
4.The lubricating oil is too
much or too little.
2. There is slap on the 1.The crosshead guide is 1.Adjust the clearance or change
power end. worn out sharply. the worn guide.
2.The bearing is worn out. 2.Change the bearing.
3.The guide is loose. 3.Tighten the bolts of guide.
4.There is water hammer on 4.Improve the suction
the fluid end. performance.

４４
 NOTE : Besides the above estimated trouble, if other abnormal phenomena are
found, The reasons should be found according to the trouble spot. After
troubleshooting, the pump can run normally.

11. Approximate Weight Of Pump Assemblies

ZYF-1300 ZYF-1600
Assemblies
lbs kg lbs kg
Pinion Shaft 3111 1411 3161 1434
Crankshaft Assy 11643 5281 13093 5939
Crosshead 3547 1609 3547 1609
Crosshead Pin & Retainer 201 91 201 91
Gear Case Cover 379 172 379 172
Suction Manifold 703 319 703 319
Discharge Manifold 487 221 487 221
One-third Fluid End
2725 1236 2725 1236
Section -Studded

12. Storage
When the pumps are not used for a long time, they should be stored.
Before storing, clean it carefully, empty each part of fluid end and clean it with water.
Discharge the engine oil in the bottom of gear box of power end completely and remove
the deposits.
Coat viscous lubricants on the finished surface of all bearings, crossheads, gears, piston
rods, extension rod etc..
Coat grease on the machined surface of each parts of fluid end.
Cover the suction inlet and discharging outlet with blind flange.
The nose end cover, rear cover and the inspection hole cover of crosshead should be
covered.

13. Explains For Order

13.1 Provided Range Of Mud Pump
-Completely mud pump basic, spray pump, pulsation dampener, safety valve, tools,
spare parts for one time change of rubber seals.
-Not including sprocket and big skid.
-If not be special required by users, spray pump is driven by belt and lubrication
pump is inner driven style by big gear.

４５
 -Normally, 6 1/2″liners and pistons are assemblied in the pump when it is transported
to users.
13.2 Styles Of Mud Pump
ZYF-series mud pumps divided into two basic styles, one is metric screws pump, the
other is American style screws pump. Users choose it due to their own demands and declare
when ordering.
14 The List of Tools ，Spare parts， Expendables and Bearing
14.1 Tools With Pump
Chart Ⅷ Tools with pump
Item
Description Qty PART No. Remarks
No.
Tools with pump 807.09.15.00
Use for disassembling cylinder
1 Cylinder head stick 1 807.09.15.01.00
head
2 Liner handling tool 1 807.09.15.02.00 Hanging liner
3 Box spanner 2-3/8″ 1 807.09.15.001 Lock nut of piston rod
Hydraulic cylinder, discharge pipe,
4 Box spanner 2″ 1 807.09.15.002 pulsation dampener，11/4″－8UN
nut
5 Box spanner 3-5/8″ 1 807.09.15.003 Main bearing bolt 3″－8UN
For liner thread ring and hydraulic
6 Box spanner 1-1/2″ 1 807.09.15.004
cylinder，1″－8UNC nut
7 Transitionally joint 1 807.09.15.005 Connect lengthening rod
8 19 5/8″lengthening rod 1 807.09.15.006 Lengthen box spanner
9 8″lengthening rod 1 807.09.15.007 Lengthen box spanner
Connect box spanner or
10 Joint 1″ 1 807.09.15.008
lengthening rod
11 24″Forcing rod 1 807.09.15.009 Joint 1″,Long box spanner
12 SH1/2-ton hoist 1 JB560-64 Hoist liner
13 Manual hydraulic pump 1 PSH—Ⅱ70MPa For hydraulic seat lifting tool
14 Hydraulic seat lifting tool 1 807.09.15.04.00 Use for pulling out valve seat
15 Charging hose 1 807.09.15.07.00 For charging dampener
16 Transition taper sleeve 1 807.09.15.010 For valve assembly blockspring

４６
Item
Description Qty PART No. Remarks
No.
17 Sleeve 1 807.09.15.011 For valve assembly blockspring
18 Long box spanner 1 807.09.15.08.00
Extension rod, crosshead
19 Allen wrench 5/8″ 1
screw1″-8UNC,upper( lower )guide
20 Bolt 1"×8UNC×6-5/8″ 4 807.09.15.013 Crosshead pin retainer
Lower valve guide Use for disassembling valve
21 1 807.09.15.09.00
retainer taken-out tool guide retainer
22 Short thread bar 1 807.09.15.014 Hydraulic seat lifting tool
14.2 Spare Part List
Supply especially spare part list for user to replace broken part. Details listed in chart Ⅸ.
Chart Ⅸ Spare Part List
Item
Description Qty Part No. Remarks
No.
Spare part list 1 807.09.17.00
Double lip seal
1 2 807.09.03.010 Pinion shaft
9.125″×10.375″×0.625″
2 Sealing ring 3 807.09.04.005 Diaphragm stuffing box
Double lip seal
3 6 807.09.04.006 Diaphragm stuffing box
5"×6.25"×0.625"
4 Capsule 1 807.09.05.13.001 Suction pulsation dampener
5 Bladder 1 807.09.16.01.00 Pulsation dampener
6 Liner seal ring 6 807.09.05.009
7 Valve cover seal 3 807.06.05.007
8 Valve rubber plate 6 807.09.05.05.003
9 Rubber plate 6 1/2″ 3 807.09.05.09.04.01.00
10 Piston seal ring 3 807.09.05.021
11 Seal gasket 2 807.09.001 Inspect door
12 Piston assy 6 1/2″ 1 807.09.05.09.04.00
13 Bumper 1 807.06.19.005 Shear relief valve
14 Shear pin 10 807.06.19.010 Shear relief valve
15 Ring gasket R39 1 807.09.16.001 Pulsation dampener
16 Ring gasket R44 3 807.09.009 Fluid end assembly

４７
 Item
Description Qty Part No. Remarks
No.
17 O-Ring Ф190×3.55 3 GB/T3452.1-1992 Diaphragm stuffing box
18 O-RingФ160×7 3 GB/T3452.1-1992 Diaphragm stuffing box
Discharge manifold and
19 O-RingФ95×5.3 3 GB/T3452.1-1992
cylinder
20 O-RingФ345×7 3 GB/T3452.1-1992 Suction manifold

21 O-RingФ185×7 3 GB/T3452.1-1992 Suction manifold and cylinder

22 O-RingФ125×7 3 GB/T3452.1-1992 Diaphragm stuffing box

23 O-RingФ200×7 3 GB/T3452.1-1992 Liner locking ring real
24 Cylinder cover seal ring 3 807.09.05.004
14.3 Expendables List
Except for spare parts listed in chart Ⅸ, those listed in chartⅩare some expendables
parts too, but part listed in chart Ⅹ are not supplied with ZYF-1300/1600 pump, users can
buy from our company or other company if they need.
Chart Ⅹ Expendables Part List
Item No. Description Qty Part No. Remarks
1 Fluid baffle disk 3 807.09.04.008
2 Extension rod 3 807.09.04.009
4 Valve spring 6 807.09.05.006
5 Piston rod 3 807.09.05.012
6 Valve AssemblyAPI7# 3 807.09.05.05.00
7 Valve body API 7# 3 807.09.05.05.001
8 Valve nut 3 807.09.05.05.002
9 Block spring 3 807.09.05.05.003
10 Locking cover 3 807.09.05.05.004
11 Valve rubber plate 3 807.09.05.05.005
12 Valve seat API7# 3 807.09.05.05.006
13 Valve guide support 3 807.09.05.05.007
14 Piston5 -1/2″～7″ 3/Sort 807.09.05.09.01.001～06.001 Six sorts totally
15 Piston core5-1/2″～7″ 3/Sort 807.09.05.09.01.01～06.01 Six sorts totally
16 Rubber plate 3/Sort 807.09.05.09.01.002～06.002 Six sorts totally
17 Piston baffle 3/Sort 807.09.05.09.01.003～06.003 Six sorts totally

４８
 Item No. Description Qty Part No. Remarks
Three sorts
18 Piston fixing spring 3/Sort 807.09.05.09.01.001～06.001
totally
Liner5 -1/2″ ～ 7″ Six sorts totally
19 3/Sort 807. 09.05.014
（Common）
Liner 5 -1/2″～7″（Double Six sorts totally
20 3/Sort 807.06.05.014 A
metal）
Piston rod clamp
21 3 807.09.05.08.00
assembly
22 Lock nut 11/2″-8UN 3 807.09.05.12.00
14.4Bearing List
Bearings of ZYF-1300/1600 pump are listed in chart Ⅺ.
Chart Ⅺ Bearing List

Item Install Bearing type Description

Qty
No Position ZYF-1300 ZYF-1600
Single row radial
Pinion shaft 4G32844H
1 2 long cylindrical
roller bearing Φ350×Φ220×98.42
roller bearing
3G4053160H 3G3003760HY Double row radial
2 Main bearing 2 Φ460×Φ300×160 Φ500×Φ300×160 spherical roller
bearing

Eccentric 928/660.4QU 929/660.4QU Single row short

3 bearing 3 Φ812.8×Φ660.4 Φ863.6×Φ660.4 cylindrical roller
×107.95 ×107.95 bearing

Double row long

Crosshead 254941 QU
4 3 cylindrical roller
roller bearing Φ285.75×Φ206.375×222.25
bearing

15 Appendix: ZYF-1300/1600 Mud Pump Parts List

Chart 1 ZYF-1300/1600 Mud Pump Main Assemblies List

Item Part No. Page

Discription
No. ZYF-1300 ZYF-1600
1 General Assembly 807.08.00 807.09.00 51

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 Part No. Page
Item
Discription
No. ZYF-1300 ZYF-1600
2 Crank Shaft Assembly 807.08.02.00 807.09.02.00 54
3 Pinion Shaft Assembly 807.08.03.00 807.09.03.00 55
4 Crosshead Assembly 807.09.04.00 807.09.04.00 56
5 Fluid End Assembly 807.09.05.00 807.09.05.00 58
6 Suction Pulsation Dampener 807.09.05.13.00 807.09.05.13.00 60
7 Lubrication Assembly 807.09.06.00 807.09.06.00 61
8 Piston & Liner Cooling System 807.09.08.00 807.09.08.00 63
9 Discharge Strainer 807.06.13.00 807.06.13.00 65
10 Accessory Manifold 807.09.14.00 807.09.14.00 65
Pulsation Dampener Charged 807.06.15.03.00 807.06.15.03.00 66
11
Hose Assembly
12 Pulsation Dampener 807.09.16.00 807.09.16.00 67
13 JA-3 Shear Relief Valve 807.06.19.00 807.06.19.00 69

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 Fig. 22 ZYF-1300/1600 Mud Pump General Assembly
Chart 2 ZYF-1300/1600 Mud Pump General Assembly Parts List
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
1 1 Frame Assembly 807.09.01.00 807.09.01.00
2 1 Crank Shaft Assembly 807.08.02.00 807.09.02.00
3 1 Pinion Shaft Assembly 807.08.03.00 807.09.03.00
4 3 Crosshead Assembly 807.09.04.00 807.09.04.00
5 1 Fluid end Assembly 807.09.05.00 807.09.05.00

５１
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
6 1 Lubrication Assembly 807.09.06.00 807.09.06.00
7 1 Skid 807.09.07.00 807.09.07.00
8 1 Piston & Liner Cooling System 807.09.08.00 807.09.08.00
9 2 Seal Gasket 807.09.001 807.09.001
10 1 Air Breather Cap 807.09.09.00 807.09.09.00
11 2 Nameplate 807.08.002 807.09.002
12 1 Crane 807.09.20.00 807.09.20.00
13 1 Hanging Frame 807.09.21.00 807.09.21.00
14 1 Frame Rear Cover Board 807.09.10.00 807.09.10.00
15 1 Seal Gasket 807.09.003 807.09.003
16 14 Bolt1/2″－13UNC×1″ AC1-1-05 AC1-1-05
17 2 Label 807.09.004 807.09.004
18 2 Bayonet Gauge 807.09.11.00 807.09.11.00
19 2 Clean Out Cover(Ⅲ) 807.09.12.00 807.09.12.00
20 2 Seal Gasket 807.09.005 807.09.005
21 8 Bolt1/2″－13UNC×1 3/8″ AC1-1-05 AC1-1-05
22 2 Crosshead Inspection Door 807.09.006 807.09.006
23 2 Seal Gasket 807.09.007 807.09.007
24 28 Bolt5/8″－11UNC×1 9/16″ AC1-1-05 AC1-1-05
25 14 Washer 12 GB/T848-2002 GB/T848-2002
26 6 Rivet 3×10 GB/T827-2000 GB/T827-2000
27 16 Bolt1″－8UNC×3 1/4″ AC1-1-05 AC1-1-05
28 16 Nut1″－8UNC AC2-1-00 AC2-1-00
29 16 Spring Washer 27 GB/T93-1987 GB/T93-1987
30 8 Washer12 GB/T848-2002 GB/T848-2002
31 4 Bolt5/8″－11UNC×1 3/4″ AC1-1-05 AC1-1-05
32 4 Nut5/8″－11UNC AC2-1-00 AC2-1-00
33 4 Spring Washer 16 GB/T93-87 GB/T93-87
34 1 Rubber Strip 40×10×5800 807.09.008 807.09.008
35 8 Capscrew M4×16 GB/T818-2000 GB/T818-2000
36 1 Pressure Gauge Resisting To Vibration YK-150,60MPa(8700psi) YK-150,60MPa(8700psi)
37 1 Discharge Elbow Assembly 807.09.14.00 807.09.14.00

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ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
38 1 Pipe Plug ZG1 1/2″ Q/ZB286.6 Q/ZB286.6
39 3 Ring Gasket R44 807.09.009 807.09.009
40 1 Discharge Strainer 807.06.13.00 807.06.13.00
41 1 Flange 807.09.010 807.09.010
42 1 Special Tools With Pump 807.09.15.00 807.09.15.00
43 1 KB-75 Pulsation Dampener 807.09.16.00 807.09.16.00
44 1 JA-3 Shear Relief Valve 807.06.19.00 807.06.19.00
45 1 Spare Parts 807.09.17.00 807.09.17.00
46 1 Frame Cover Board Assembly 807.09.18.00 807.09.18.00
47 1 Lubricating Pump Assembly 807.09.22.00 807.09.22.00
48 1 Loctite（ Thread Socker ）277 277 277
49 Shim Set 807.09.012 807.09.012

Fig. 23
ZYF-1300/1600 Crank Shaft Assembly

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 Chart 3 ZYF-1300/1600 Crank Shaft Assembly Parts List
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
1 2 Main Bearing Cover 807.09.02.01.00 807.09.02.01.00
2 1 Bearing Carrier, Right 807.08.02.001 807.09.02.001
3 2 Seal Gasket 807.09.02.002 807.09.02.002
4 2 Inner Race Retainer 807.09.02.003 807.09.02.003
5 3 Outer Race Retainer 807.08.02.02.00 807.09.02.02.00
6 3 Eccentric Strap（Connection Rod） 807.08.02.004 807.09.02.004
7 1 Inner Race Retainer (Ⅰ) 807.09.02.005 807.09.02.005
8 1 Crank Shaft 807.09.02.03.00 807.09.02.03.00
9 1 Inner Race Retainer (Ⅱ) 807.09.02.006 807.09.02.006
10 1 Eccentric Ring Gear 807.08.02.005 807.09.02.04.00
11 12 Bolt 1 1/2″-8UN-51/2″ 807.09.02.007 807.09.02.007
12 2 Spacer 807.09.02.008 807.09.02.008
13 1 Bearing Carrier, Left 807.08.02.009 807.09.02.009
14 2 Outer Race Retainer 807.08.02.010 807.09.02.010
15 2 Inner Race Retainer 807.09.02.011 807.09.02.011
16 4 Main Bearing Bolt 807.09.02.012 807.09.02.012
17 Shim Set 807.09.02.013 807.09.02.013
18 2 Bolt 5/8″-11UNC-4 3/4″ 807.09.02.014 807.09.02.014
19 12 Locking Nut1 1/2″-8UN 807.09.02.05.00 807.09.02.05.00
20 72 Bolt 5/8″-11UNC-1 9/16″ 807.09.05.015 807.09.05.015

21 28 Bolt 5/8″-11UNC-1 3/4″ AC1-1-05 AC1-1-05

22 3 Eccentric bearing 807.08.02.06.00 807.09.02.06.00

23 2 Main Bearing 807.08.02.07.00 807.09.02.07.00
24 28 Washer16 GB/T848-2002 GB/T848-2002
25 40m Safety WireΦ1.5 GB/T343-1994 GB/T343-1994
26 3m Safety WireΦ3 GB/T343-1994 GB/T343-1994
27 920ml Loctite242 242 242
28 2 Bolt 5/8″-11UNC-4″ 807.09.02.016 807.09.02.016

５４
 Fig. 24 ZYF-1300/1600 Pinion Shaft Assembly
Chart 4 ZYF-1300/1600 Pinion Shaft Assembly Parts List
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
1 2 Key2″×2″×11 3/8″ 807.09.03.001 807.09.03.001
2 1 Pinion Shaft 807.08.03.002 807.09.03.002
3 2 Oil Seal Wear Ring 807.09.03.003 807.09.03.003
4 2 Oil Seal Carrier 807.09.03.004 807.09.03.004
5 2 Oil Seal Carrier Gasket 807.09.03.005 807.09.03.005
6 2 Gasket 807.09.03.006 807.09.03.006
7 2 Pinion Bearing Carrier 807.06.03.007 807.09.03.007
8 2 Outer Race Retainer 807.09.03.008 807.09.03.008
9 2 Seal Gasket 807.09.03.009 807.09.03.009
807.09.03.01.00 807.09.03.01.0
10 2 Oil Box
0
11 24 Bolt 1/2″-13UNC×1-3/8″(35) AC1-1-05 AC1-1-05
12 16 Bolt 7/8″-9UNC×2″（50.8） AC1-1-05 AC1-1-05
13 2 Oil Seal9.125″×10.375″×0.625″ 807.09.03.010 807.09.03.010
14 2 Bearing4G32844H 807.09.03.011 807.09.03.011
15 24 Locking Washer 24 GB/T93-1987 GB/T93-1987
16 16 Lock ingWasher14 GB/T93-1987 GB/T93-1987
17 1 Flange ( Tool ) 807.09.03.012 807.09.03.012
18 3 Bolt5 /8″-11UNC×1-3/4″(44.45) AC1-1-07 AC1-1-07
19 3 Locking Washer16 GB/T93-1987 GB/T93-1987

５５
 Fig. 25 ZYF-1300/1600 Crosshead Assembly
Chart 5 ZYF-1300/1600 Crosshead Assembly Parts List
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
1 1 Crosshead 807.09.04.001
2 1 Crosshead Guide（Upper） 807.09.04.002
3 8 Shim Set 807.09.04.01.00
4 2 Adjusting Gasket 807.09.04.003
5 1 Diaphragm Stuffing Box 807.09.04.004
6 1 Sealing Ring 807.09.04.005
7 1 O-ring Φ190×3.55 GB/T3452.1-1992
8 2 Double lip Seal5″×6.25″×0.625″ 807.09.04.006

５６
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
9 1 Locking SpringΦ3.2 807.09.04.007
10 1 Fluid Baffle Disk 807.09.04.008
11 1 Crosshead Extension 807.09.04.009
12 1 Crosshead Pin 807.09.04.010
13 1 O-ring Φ125×7 GB/T3452.1-1992
14 8 Bolt 3/4″-10UNC-2 1/2″ 807.09.04.011
15 1 Seal Gasket 807.09.04.012
16 1 O-ring Φ160×7 GB/T3452.1-1992
17 1 Crosshead Guide（Lower） 807.09.04.013
18 1 Crosshead Pin Retainer 807.09.04.014
19 1 Crosshead Bearing 807.09.04.02.00
20 2 Male Connector 3/8″ 807.09.04.015
21 2 Bolt 1″-8UNC-2 3/8″ 807.09.04.016
22 6 Bolt 1″-8UNC-2 3/4″ 807.09.04.017
23 8 Locking Plate 807.09.04.018
24 4 Bolt 3/8″-16UNC-1″ AC1-1-05
25 8 Capscrew1″-8UNC-2 5/8″ 807.09.04.019
26 4 Locking Washer10 GB/T93-1987
27 Wire L=300 Φ1.6 GB/T4240-1993
28 Loctite242 242

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 Fig. 26ZYF-1300/1600 Fluid End Assembly
Chart 6 ZYF-1300/1600 Fluid End Assembly Parts List
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
1 3 Fluid Cylinder Studded Assy 807.09.05.01.00
2 3 Cylinder Head Flange（Thread Ring） 807.09.05.001
3 3 Cylinder Head 807.09.05.002
4 3 Lower Valve Guide Retainer 807.09.05.02.00
5 3 Valve Guide ，Lower 807.09.05.03.00
6 3 Cylinder Head Plug 807.09.05.04.00
7 3 Alignment Ring 807.09.05.003
8 3 Head Seal 807.09.05.004
9 1 Discharge Manifold 807.09.05.005
10 6 Valve Spring 807.09.05.006
11 3 O-ring Φ95×5.3 GB/T3452.1-1992

５８
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
12 6 Valve Assy 807.09.05.05.00
13 3 Valve Cover Seal 807.09.05.007
14 3 Valve Cover 807.09.05.008
15 6 Liner Seal Ring 807.09.05.009
16 3 Wear Plate 807.09.05.010
17 3 Liner Thread Ring 807.09.05.011
18 3 Liner Lock 807.09.05.06.00
19 3 Piston Rod 807.09.05.012
20 1 Pipe 807.09.05.07.00
21 3 O-ring Φ200×7 GB/T3452.1-1992
22 3 Liner Lock Ring 807.09.05.013
23 3 Liner（ 5 1/2″，6″，61/4″，61/2″，63/4″，7″） 807.09.05.014
24 3 Piston Rod Clamp 807.09.05.08.00
25 3 Liner End Cover 807.09.05.015
26 3 Piston Assy 807.09.05.09.00
27 18 Bolt 7/8″-9UNC-2 1/2″ AC1-1-07
28 1 Suction Manifold 807.09.05.10.00
29 4 Shim Set 807.09.05.11.00
30 3 Valve Guide ，Upper 807.09.05.016
31 16 Stud11/2″-8UN×10 5/8″ 807.09.05.017
32 44 Nut 11/2″-8UN 807.09.05.018
33 3 Valve Guide Retainer 807.09.05.019
34 12 Bolt 3/8″-16UNC-3/4″ 807.09.05.020
35 3 Piston Seal 807.09.05.021
36 3 Piston Nut 807.09.05.12.00
37 3 O-ring Φ185×7 GB/T3452.1-1992
38 1 Suction Pulsation Dampener 807.09.05.13.00
39 3 O-ring Φ345×7 GB/T3452.1-1992
40 1 Suction Flange （I） 807.06.05.022
41 1 Suction Flange （Ⅱ） 807.06.05.023
42 36 Nut 1″-8UNC AC2-1-00
43 24 Bolt 1″-8UNC-3 1/2″ AC1-1-05

５９
ITEM PART No.
QTY DISCRIPTION
No. ZYF-1300 ZYF-1600
44 1 WireΦ1.6 L=1830 GB/T4240-1993
45 1 Pipe Plug NPT1 1/2″ 807.09.05.024
46 12 Stud11/2″-8UN×22 3/16″ 807.09.05.025
47 Loctite277 277
48 1 Suction Block 807.09.05.026
49 1 Discharge Block 807.09.05.027
50 30 Washer39 807.09.05.028
51 12 Bolt 1″-8UNC-3 1/4″ AC1-1-05

Fig. 27 ZYF-1300/1600 Suction Pulsation Dampener

Chart 7 ZYF-1300/1600 Suction Pulsation Dampener Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Capsule 807.09.05.13.001
2 1 Cover 807.09.05.13.002

６０
 Fig. 28 ZYF-1300/1600 Lubrication Assembly
Chart 8 ZYF-1300/1600 Lubrication Assembly Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Key 3/16″×3/16″×1″ 808.09.06.001
2 1 Oil Pump Gear Assy 807.09.06.01.00
3 2 Right-angled JointNPT1/4-3/8 807.09.06.002
4 2 Bolt 3/4″-16UNF 807.09.06.003
5 4 Bolt 5/16″-18UNC-1 9/16″ 807.09.06.004
6 2 Joint A16 JB/ZQ4410-86
7 3 Joint A8 JB/ZQ4410-86
8 14 Right-angled JointNPT1/4″-1/4″ 807.09.06.007
9 1 Copper PipeΦ8×1×305 GB/T1527-1997
10 17 Joint A8 JB/ZQ4408-86
11 1 Manifold Ⅱ 807.09.06.009
12 2 Joint A16 JB/ZQ4408-86
13 1 Copper PipeΦ16×1.5×686 GB/T1527-1997

６１
 PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
14 1 Copper PipeΦ16×1.5×331 GB/T1527-1997
15 2 Tube ClampⅡ 807.09.06.02.00
16 2 45°Joint 807.09.06.011
17 1 Copper PipeΦ10×1×838 GB/T1527-1997
18 2 Copper PipeΦ12×1×305 GB/T1527-1997
19 1 Tube ClampΦ8 807.09.06.03.00
20 3 Copper PipeΦ8×1×762 GB/T1527-1997
21 2 Copper PipeΦ8×1×508 GB/T1527-1997
22 2 Copper PipeΦ8×1×229 GB/T1527-1997
23 5 Pipe PlugNPT1/4″ 807.09.06.012
24 1 Copper PipeΦ8×1×915 GB/T1527-1997
25 1 Copper PipeΦ8×1×1194 GB/T1527-1997
26 1 Copper PipeΦ8×1×1016 GB/T1527-1997
27 1 Manifold Ⅰ 807.09.06.013
28 2 Joint A10 JB/ZQ4408-86
29 4 Tube ClampⅠ 807.09.06.04.00
30 2 Seal Copper Washer GB/T5651-1985
31 4 Bolt 1/4″-20UNC-3/4″ AC1-1-05
32 2 Muzzle 807.09.06.015
33 2 Copper PipeΦ12×1×610 GB/T1527-1997
34 2 Copper PipeΦ8×1×813 GB/T1527-1997
35 2 Joint A8 GB/T5628.1-1985
36 3 Tube Clamp-DoubleΦ8 807.09.06.05.00
37 1 Copper PipeΦ10×1×1956 GB/T1527-1997
38 1 Copper PipeΦ8×1×1956 GB/T1527-1997
39 1 Copper Pipe Φ8×1×2311 GB/T1527-1997
40 1 Copper Pipe Φ8×1×1600 GB/T1527-1997
41 1 Copper Pipe Φ8×1×1245 GB/T1527-1997
42 1 Joint NPT1/4″-1/4″ 807.09.06.016
43 1 Copper Washer 807.09.06.017
44 2 Shim Set 807.09.06.06.00
45 1 Oil Pump Mtg Plate 807.09.06.07.00

６２
 PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
46 1 Joint A10 GB/T5628.1-1985
47 4 Spring Washer 8 GB/T93-1987
48 1 Relief Valve YYFJ-L20
49 4 Spring Washer 6 GB/T93-1987
50 1 Gear Oil Pump 2S
51 1 Pressure Gauge (0～1.6MPa) Y60-Z(NPT 1/4″)
52 4 Joint A12 JB/ZQ4408-86
53 1 Oil Filter 807.09.06.08.00
54 Loctite609 609

Fig. 29 ZYF-1300/1600 Piston & Liner Wash

Chart 9 ZYF-1300/1600Piston & Liner Wash Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Belt Guard 807.09.08.01
2 1 Sheave 807.09.08.001
3 1 V Belt A3708 GB/T1171-1996

６３
 PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
4 1 Orientation Ring Support Assy 807.09.08.02
5 2 Elbow 90°NPT1″ 807.09.08.002
6 1 Connector NPT1″-G1″ 807.09.08.003
7 1 Connector NPT1″ 807.09.08.004
8 1 Connector G1″-11/4″-12UNF 807.09.08.005
9 1 Hose L=750 φ38×φ53
10 1 Pipe Clamp No.3
11 1 Connector ZG 2 1/2″ 807.09.08.006
12 1 Elbow 90° ZG 2 1/2″
13 1 Connector ZG 2 1/2″-NPT2 1/2″ 807.09.08.007
14 1 Hose Assy 807.09.08.06.00
15 1 Pump Support 807.09.08.03
16 2 Connection Plate 807.09.08.008
17 4 Bolt 3/4″-10UNC-1 1/4″ AC1-1-05
18 4 Spring Washer 20 GB/T93-1987
19 8 Washer20 GB/T97.1-2000
20 1 Tank 807.09.08.04
21 1 Tank Cover 807.09.08.05
22 1 Connector ZG 2 1/2″ 807.09.08.009
23 1 Centrifugal Spray Pump 32PL
24 1 G1″ Globe Valve Q11F-16
25 2 Washer 807.09.08.010
26 2 Flange 1″ 807.09.08.011
27 2 Bolt 5/16″-18UNC-1″ AC1-9-05
28 8 Bolt 1/2″-13UNC-2 1/2″ AC1-1-05
29 8 Nut1/2″-13UNC" AC2-1-00
30 12 Spring Washer 14 GB/T93-1987
31 4 Bolt 1/2″-13UNC-1 3/4″ AC1-1-05
32 4 Washer12 GB/T96.2-2002

６４
 Fig. 30 ZYF-1300/1600 Discharge Strainer Assembly
Chart 10 ZYF-1300/1600 Discharge Strainer Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Strainer Housing 807.06.13.001
2 1 Strainer 807.06.13.01.00
3 1 O-Ring Φ165X7 GB/T3452.1-1992
4 8 Stud1 1/2″-8UN×4 3/8″ 807.06.13.002
5 8 Nut1 1/2″-8UN 807.06.05.01.003

Fig. 31 ZYF-1300/1600 Accessory Manifold Assembly

６５
 Chart 11 ZYF-1300/1600Accessory Manifold Parts List

PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Pressure Gauge Seat 807.09.14.01.00
2 1 Elbow Assy NPT3″ 807.09.14.02.00
3 1 Elbow Assy 807.09.14.03.00
4 16 Stud1″-8UNC×6 5/8″ 807.09.14.001
5 32 Nut1″-8UNC 807.09.14.002
6 2 Ring Gasket 807.09.14.003
7 Loctite 277

Fig. 32 Pulsation Dampener Charged Hose Assembly

Chart 12 Pulsation Dampener Charged Hose Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Nut G5/8″ 807.06.15.03.001
2 1 Sealing Connector 807.06.15.03.002
3 1 Connector 807.06.15.03.003
4 1 Gasket 807.06.15.03.004
5 1 Pipe Plug 807.06.15.03.005
6 1 C Type Hose M14×1.5 JB1838-77

６６
 Fig. 33 KB-75 Pulsation Dampener Assembly
Chart 13 KB-75 Pulsation Dampener Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Sealing Ring R39 807.09.16.001
2 1 Bottom Plug 807.09.16.002
3 1 Bladder 807.09.16.01.00
4 1 Studded Assy 807.09.16.02.00
5 1 Head 807.09.16.003
6 1 Steel Pipe Tee NPT1/4″ 807.09.16.004
7 1 Connector 807.09.16.005
8 1 Pressure Gauge Cover Assy 807.09.16.03.00
9 1 Purge Valve PJC1-L8
10 1 Double Scale Pressure Gauge Y-60（NPT1/4″）
（0～25MPa）（0～3630psi）
11 1 Needle Valve （NPT1/4″） JZR3-L8
12 1 Washer 14 807.09.16.006

６７
 ※Charging Instructions
1. Remove dampener gauge cover. Bleed off any existing pressure in gage area by turning
purge valve cap approximately 1/4 to 1/2 turn. Remove purge valve.
2. Connect charging hose to dampener charging valve and nitrogen cylinder valve.
3. Open dampener charging valve.
4. Open cylinder valve slowly. Use this valve to regulate flow to dampener.
5. When dampener gauge shows desired charging pressure, close cylinder valve.
6. Close dampener valve.
7. Remove hose from dampener charging valve and replace gage cover.
8. For best results dampener precharge pressure should be not more than 2/3 of pump
discharge pressure. Maximum precharge 650 psi.
CAUTION: USE ONLY COMPRESSED NITROGEN OR AIR，DO NOT
CHARGE WITH OXYGEN.

Fig. 34 ZYF-1300/1600 Shear Relief Valve Assembly

６８
 Chart 14 ZYF-1300/1600 Shear Relief Valve Parts List
PART No.
ITEM No. QTY DISCRIPTION
ZYF-1300 ZYF-1600
1 1 Adapter 807.06.19.001
2 1 Plain Washer 807.06.19.002
3 1 Plunger Seal 807.06.19.01
4 1 Body 807.06.19.003
5 1 Plunger Stem 807.06.19.004
6 1 Bumper 807.06.19.005
7 1 Roll Pin 807.06.19.006
8 1 Cover Spring 807.06.19.007
9 1 Cover 807.06.19.008
10 1 Shear Bar 807.06.19.009
11 1 Shear Pin 807.06.19.010
12 1 Warning Plate 807.06.19.011
13 1 Shear Bar Pin 807.06.19.012
14 2 Retainer Ring 807.06.19.013
15 1 Name Plate 807.06.19.014
16 1 Cotter Pin 4X26 GB/T91-2000
17 2 Nut M4 GB/T41-2000
18 2 Capscrew M4×16 GB/T67-2000
19 1 Bolt 3/8″-16UNC×4-3/8″ AC1-1-05
20 1 Nut 3/8″-16UNC AC2-1-00
21 4 Capscrew M3×8 GB/T67-2000
22 Loctite 569 569

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Address: No.465, North of Daqing Road, Hualong District, Puyang City, Henan
Province,China
Postcode: 457001
Tel: 086-0393-5380092 5380088 5380098
Fax: 086-0393-5380188
E-mail: [email protected]
Http: //www.zpebmach.com

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