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• Victor Timana Silva

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Instruction Manual For ZB400

Plunger Pump

Texas First Industrial Corporation 32473 Morton Road, Brookshire, TX 77423, USA. Phone: 001-281-934-1190• Fax: 001-281-395-8931• www.tfi-corp.com

INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

Index 1. General…………………………………………………………….4 2. Main Technical Specifications……………………………………4 3. Main Structural features…………………………………………..4 4. Installation of New Pump……………………………………….. .9 5. Operation of the Pump…………………………………………. 10 6. Maintenance …………………………………………………….. 11 7. Troubleshooting…………………………………………………..18 8. Conventional Spare Parts and Tool List………………………. 18 Affixture: ZB-400

PLUNGER PUMP PARTS LIST

3

INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

1. General ZB400 plunger pump is of horizontal single acting reciprocating pump.. It consists of power end, fluid end reducer and lubricating system. It is mainly used for circulating system of work over, wash well, cement well and drilling operations. 2. Specifications 2.1 Technical parameters Max horse power) 400HP * 298kW+ Max rod load) 100000lbs* 45360kg+ Stroke length) 6"* 152.4mm+ Gear ratio) 4.57) 1 Outlet diameter) L95.25"W64.5"H66" 2420×1638×1676mm Weight(Approx): 10560lb (4800kg) (Include oil tank and skid) 2.2 Prformance data PLUNGER

OUTPUT

DIAMETER

PER REV

DISPLACEMENT AT PUMP STROKES PER MINUTE/PINION RPM 50/229

100/457

200/914

300/1371

400/1828

In

gpr

gpm

PSi

gpm

PSi

gpm

PSi

gpm

PSi

gpm

PSi

(mm)

(lpr)

(lpm)

(MPa)

(lpm)

(MPa)

(lpm)

(MPa)

(lpm)

(MPa)

(lpm)

(MPa)

4"

0.98

49

8000

98

6370

196

3150

294

2100

392

1560

(101.6)

(3.7)

(185)

(56)

(371)

(44.4)

(742)

(22)

(1113)

(14.8)

(1484)

(11)

4.5"

1.24

62

6000

124

5030

248

2485

372

1660

496

1220

(114.3)

(4.7)

(235)

(42)

(470)

(35)

(940)

(17.5)

(1408)

(11.7)

(1880)

(8.6)

Note Based on 100% volumetric efficiency and 90% Mechanical efficiency.

2.3 Pump Overall Dimension (See Fig. 1) 2.4 Diameters of Suction and Discharge Manifold Dia. of Suction Manifold

6” (ANSI-150#)

Dia. Of Discharge Manifold

2”(1502 Union)

3. Main Structural Features 3.1 Power End Crankshaft is integral alloy forged with three crank and five support positions. It consists of gearbox, crankshaft, connection rod, cross head, cross head pin and roller bearing, etc. It features simple in structure, high in strength and rigidity, light in weight and longer in service life.(See fig.2) 3.1.1 Frame is box type welded with low carbon steel plate, which features high anti bending stress. 4

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Fig.2 3.1.2 Crankshaft is integrally forged with high loading capacity and anti fatigue stress. 3.1.3 Connection rod and crass head is alloy-casting pieces. 3.1.4 Crosshead pin is alloy-steel forged. 3.1.5 Sleeve of big end for connection rod is specially aluminum made wear resistant casting piece. 3.1.6 Sleeve of small end for connection rod is albronze-casting piece. 3.2 Gear Reducer: The housing is welded with low carbon steel plate. Gear and gear reducer is forged and especially heat-treated. It features high driving capacity and efficiency because herringbone gear drive is used. 3.3 Fluid End Fluid end consists mainly of module, suction and discharge valve assembly, suction and discharge spring, suction and discharge pipe, plunger, packing, safety valve and pressure regulator, etc. (See fig.4) 3.3.1 Module is alloy-forged piece with special heat treatment. The surface is nickel-plated for weak acid resistant feature. 3.3.2 Structure and dimension of suction and discharge valves are same for easy interchanging and maintenance. 3.3.3 Suction and discharge springs are made of No 65 Mn steel with surface galvanization. Suction spring with 4 mm in diameter is softer than discharge spring, which is 5 mm in diameter. These two springs shall not be misused. 3.3.4 Suction pipe is welded with seamless pipe. 3.3.5 Discharge pipe is 2"-1502 union fitting.

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Fig.3 3.3.6 Plunger is alloy-steel forged with wear resistant sintered-carbide plated surface. It features good wear resistant and anti corrosion properties and longer service life. 3.3.7 Packing is V shaped. It is made of propyl cyanide rubber with cloth for safety sealing. 3.3.8 Safety valve is shear and full open structure. It will discharge load automatically once the system is overloaded for safety operations. The safety valve consists 35 MPa and 21 MPa. 35 MPa safety valve with 6.5 mm in diameter is red marked while 21 MPa safety valve with 5.1 mm in diameter is yellow marked. 3.3.9 Pressure regulator is low carbon plate welded with optimum pressure regulating effect, especially at small strokes. 3.4 Lubricating System Lubricating system consists of two independent parts for power end and fluid end respectively. It is compulsory pressure lubricating. The system includes gear oil pump, swing oil ejector, overflow valve, rough and fine filters, oil resistant hose and oil tank, etc. 3.4.1 Lubricating system at power end is responsible for lubricating of crankshaft, sleeves at two ends of connection rod, cross head, gear pair and all roller bearings. It ensures normal operation of these working parts and prolongs the service life. See Fig. 5 for the oil-lubricating path.

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Fig.4

Fig.5

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3.4.2 Gear oil pump of power end installed on the shaft end of input shaft. 3.4.3 Lubricating system of fluid end is used to lubricate packing and plunger. It reduces friction force and working temperature of plunger and packing, prolongs service life of plunger and packing. See Fig. 6.

Fig.6 4. Installation of New Pump ZB400, pump has been completely assembled and test operated under pressure before being shipped to the field. The lubrication is drained from the power end. Before putting the pump into service, the following precautions and operations must be performed and checked. In order to prevent personal injury during the performance of any maintenance or inspection procedures, this pump 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 ZB400, plunger pump is suitable for most any type of installation. It shall 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 and operation. 4.2 Suction System Requirements The suction of the ZB400, pump must have a positive head (pressure) for satisfactory performance. The optimum suction manifold pressure is 0.1 – 0.2 MPa for maximum volumetric efficiency and expendable parts life. This head pressure is best supplied by a centrifugal pump. 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 mo9nifold and centrifugal pump. It also effects the normal operation of safety valve.

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4.3 Oil Lubrication The lubrication for ZB400, pump is drained before delivery to the field. Add the proper type and quantity of lubrication in the pump before operation in the field. Add oil to the hoist point shown by oil scale or the window at the first time and run for 10 to 15 minutes. Add some more oil after the oil level is stable to fill those left in pump case and lubricating pipe. Fill the power end oil tank with middle class pressure gear oil, sulfuric acid type, as follows: Oil

Quantity(liter) #

-1-

. +68-

N320(6 EP)

-18-

. +27-

N220(4#EP)

-29- . +4-

250

#

N150(1 EP)

Fill the fluid end oil tank with mechanical oil 20# quantity 25L 5. Operation of the Pump 5.1 Start the Pump 5.1.1 Preparations before Starting * Check for tightness of each fastener. * Check for proper status for valves, open or close as required. * Check for oil quantity at oil tank as required. * Manual rotates the driving shaft to make the pump rotate a round. Make sure the rotation is smooth. 5.1.2 Starting Start prime mover to drive the pump only the preparation work is completed. 5.2 Operation Instruction 5.2.1 Increase the pump pressure gradually and reach to working pressure after 10 to 15 minutes. 5.2.2 Check for oil pressure of lubricating system displayed in the pressure meter during operation. The oil pressure shall be within 0.2 – 1 MPa. 5.2.3 Check for pump stroke meter during operations. The pump stroke shall not exceed 360 min-1. 5.2.4 Check for pressure gauge during operations. Max. pressure of the pump shall not exceed rated pressure (as per 2.2 performance date). 5.2.5 Observe running conditions during the pump operation. Stop the pump for repairing timely if non-normal phenomenon is found. It is forbidden to repair the pump while operation. 5.3 Stop the Pump 5.3.1 Reduce the pressure gradually to zero after the work is completed. Pump clean water to clear the discharge manifold. Stop the pump after the water

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becomes clean. 5.3.2 Drain remained water at fluid end at very cold days to prevent module. 6. Maintenance 6.1 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. 6.1.1 Safety Wires Open the fluid end cover; check safety wire on all bolts including the main bearing hold-down bolts on crankshaft, bolts on connection rod and guide plate. Replace new wires after all bolts are retightened. 6.1.2 Gearbox Check for any non-normal wear on the gears. There may be some spots on the surface in the running-in period. This is the initial spot and will not affect the gears service life. During routine inspections, if the spot becomes bigger gradually, contact the pump manufacturer at once for complete inspection of the gears. 6.1.3 Cross Head and Guide Plate Check for wear of cross head and guide plate. Change for new if non-normal phenomenon is observed, as this may damage bearings and others. 6.1.4 Pony Rod Check for bolts tightness of pony rod and crosshead. Tighten loosed bolts and check for proper sealing. Otherwise change the sealing. 6.1.5 Coupling Check for bolts tightness on the coupling. Tighten loosed bolts and change lock wire. Change for new one if the coupling is broken. 6.2 End Make sure all valves on the discharge side of the pump are opened before the pump is put into operation. The load shall be increased gradually. Do not operate the pump if there is no fluid. When pump is to be shut down or not operated for a period of 30 days or more, it is recommended that the fluid end parts such as plungers, suction and discharge valves, 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 module hoses and valve seat, etc. This will extend the life of the fluid end greatly. A few of the obvious points for maintenance of the fluid end are as follows (refer to Fig. 4): 6.2.1 Module (refer to Fig. 4) The three separate fluid cylinder modules are connected to power end frame through studs and nuts. Alignment with the power end frame bores is obtained through the liner and position bore on fluid end. Special wrench is provided for 11

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tightening of nuts. It is easier for the user to install and detach while in maintenance. 6.2.2 Suction Manifold (refer to Fig. 4) The suction manifold is connected to each module by studs and nuts and is sealed through the O-ring in the connection surface. Thus, screw studs to the module, clean the oil ring groove and put the oil ring and then tighten the studs before the suction manifold is installed. 6.2.3 Packing Change (refer to Fig. 7) Detach the plunger (1), pressing nut (2), oil seal (3) guide sleeve (4) packing (5) and retainer (6) from the liners to be changed using and cylinder head puller. Put the detached parts in order separately. In this way, if problem is observed, cause will be easy to be determined.

Fig.7

Fig.8 Cylinder head puller Clean the dirty things like mud while observing the inside liner. Before re-install the packing, clean all the parts detached and replace the damaged. Rotate the packing into the liner hole and if it is jammed, wood hammer it lightly. The plunger shall be greased before it is put into the liner. The pressing plate shall not be too tightening. The proper way is that there is no clearance between 12

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the packer, guide sleeve and oil seal. 6.2.4 Changing of Discharge Valve Assembly (refer to Fig. 9)

Fig.9 * Use the cylinder head puller to detach screw gland (1) and valve gland (2) * Take out the discharge spring (3) * Take out the valve assembly (4) * Use the valve seat puller to take out the valve seat (5) Check for damage at cone surface of module and oil seal (6), (7) and (8). Repair or replace the damaged. Caution: After the valve seat (5) is mounted, use copper bar to hammer top surface of valve seat for compact contact between the valve seat and cone surface of the module. Pay attention the cone surface shall not be damaged. 6.2.5 Changing of Suction Valve Assembly (refer to Fig. 11) * Use the cylinder head puller to detach screw gland (7) and cylinder head (6) * Manual rotate the pump to withdraw the plunger at module to rear dead point * Remove the circlip from position groove at module by screwdriver. * Rotate the spring support (5) at 90º to take it out. * Take out Suction spring (4) * Take out suction valve assembly (3)

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Fig. 10 Check for damage at cone surface of module and oil seal (1) and (8). Repair or replace the damaged. Caution: After the valve seat (2) is mounted, use copper bar to hammer top surface of valve seat for compact contact between the valve seat and cone surface of the module. Pay attention the cone surface shall not be damaged. 6.2.6 Changing of Suction Valve Seat(See fig 11) * Put the lever device (3) of valve seat puller from module top to make the driver block to connect to the lower end surface of suction valve as shown in Fig. 12. * Put the position block (2) into the screw hole on top of module * Screw the nut (1) on screw bar and rotate, jolt the top end of the screw bar with hammer simultaneously to pull out the valve seat. 6.3 Lubricating System Adequate lubrication of the pump is the most important single factor affecting the ultimate service life of the pump. 6.3.1 Pressure of Lubricating System Observe the lubricating pressure as shown in the pressure gauge frequently while the pump is in operation. Oil pressure shall be within the range of 0.2 – 1 MPa. Check for following items if oil pressure is decreased. * Suction filter is plugged or not. * Whether the oil level is too low. * Whether the coupling is loosen or broken. * Whether oil pump is wear or broken. * Whether the over flow valve is in trouble.

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Fig. 11 Check for following items if oil pressure is increased. * Whether the oil path is plugged. * Whether the over flow valve is not in operation. * Whether the pressure gauge is broken. 6.3.2 Oil Level Check for oil level at oil tank of power end and oil ejector. Oil level shall at top of the oil scale. 6.3.3 Lubricating Path Check for all lubricating path and pipe, ensure they are complete and through. Check for proper status of inlet and outlet hose of gear pump. Check for leakage of all oil pipe connectors. 6.3.4 Oil Filter 6.3.4.1 Oil filter cleaning method Self sealing magnetism oil filter(CXL-100×80L) is mounted on ZB-400, Features) 1 + During the disassembly of the oil filter, the automatic valve can be automatically closed to prevent discharging of lubricant oil. It’s not necessary to 15

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drain the oil in the oil tank for easy operation. 2+ Permanent magnet is installed in the oil filter to absorb the metal substance. 3+ A by-pass valve is equipped and can be open automatically to protect the pump form damage when the oil filter is blocked.

1.Center screw 2.Plug 3.By-pass valve 4. Permanent magnet 5. Mandril 6. Self-sealing valve 7. Filter screen 8. Press cap

Fig.12 Filter screen structure 6.3.4.2 Disassembly operation of the oil filter Remove the center screw(1), mandril(5). Pull the filter screen out.(6) The self sealing valve will seal the oil in the oil tank. 6.3.4.2.1 Remove the press cap. It will be normal that some oil in the drainer flow out. 6.3.4.2.2 Disassemble the strainer and the mandril. Wash and clean the drainer and the permanent magnet to remove the sticking feculence by pure gasoiline or diesel. 6.3.4.2.3 Assemble the mandril* pay attention to the direction+ ,filter screen, spring in turn. Tighten the press cap. The assembly with be done after screwing on the center screw. Note) During the assembling of the mandril, the end with shoulder should be installed inside and the round end should be installed outside. Make sure the sealing element should be assembled in right way.( See the details in Fig 12)

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6.3.4.3 Caution Performance test of ZB-400, mud pump have be done before the delivery .The oil filter has been cleaned couples of times. The initial period of the operation is running-in period to the mud pump. It is unavoidable that the filter screen will be jammed by the feculence. Make sure to pay attention to the change of oil pressure gauge frequently. If the pressure is lower than 0.05MPa, the oil filter should be cleaned as soon as possible. During the initial period of the operation, the filter should be washed and cleaned at least one time per week. The cleaning period will be prolonged accordingly after above mentioned period. In the meantime, the lubrication oil should be replaced periodically. For the first time, the lubrication oil should be replaced within one week. For the second time, the lubrication oil should be replaced within two weeks. The lubrication oil should be replaced in accordance with instruction Manual after two times replacement. The lubrication oil should be replaced no later than six months. Before replacement of lubrication oil, the operator should wash and clean the oil tank and the guide cavity. Pump the oil by te filter. Inspect the oil pipelines and make sure there’s no any block in the oil pipeline. 6.3.5 Lubricating Oil Periodically check for the lubricating oil status. Change for new oil frequently as moisture, water, and dust in the air and medium will affect the oil. 7. Troubleshooting Phenomenon Pump jolt Big swing of pressure gauge Short packing life Packing in smoke Clouding oil

Cause Loose bolts on connection rod

Tighten Blots

Sleeve of connection rod damage

Change for new

Valve or spring damage

Change for new

Valve or spring damage

Change for new

Insufficient pump suction

Increase charging pressure

Lubricating system jam

Check lubricating system

Wear out plunger

Change new plunger

Lubricating system jam

Check lubricating system

Insufficient oil

Check oil tank

Pressing nuts too tight

Adjust pressing nut

Water atomizing or leakage

Change oil and clean filter

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8

Conventional spare parts and tools

8.1.Conventional spare parts Item

Code

Name

Qty

1

ZB-03Y-01

Plunger seal assy

3sets

2

ZB-03Y-06

Valve assy

6pcs

3

ZB-03Y-10

Suction spring

6pcs

4

ZB-03Y-05

Discharge spring

6pcs

5

GB3452.1-97.5x5.3

Seal for valve seat

6pcs

6

GB3452.1-115x5.3

Seal for cylinder head

6pcs

7

ZB-03Y-20-03

35MPa pin(red)

3pcs

8

ZB-03Y-20-02

21MPa pin(yellow)

3pcs

9

ZB-03Y-20-06

Buffer ring

2pcs

10

ZB-03Y-20-09

Piston

2pcs

11

ZB-03Y-06-02

Insert

12pcs

12

JB/ZQ4265-86

Yx Seal D90

3pcs

8.2.Tools list Item

Code

Name

1 ZB-05Y-01

Puller cylinder head

1set

2 ZB-05Y-02

Puller for valve seat

1set

3 ZB-05Y-03

Tools for crosshead pin

1set

4 ZB-05Y-05

Rod

1set

5 ZB-05Y-06

60/1 1/2”Socket spanner

1pce

6 NB-07Y-05GJ

20” Force rod

18

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

ZB-400, PLUNGER PUMP

PARTS LIST

19

INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

TABLE OF CONTENTS

FRAME & MISCELLANEOUS PARTS

…………………………

21

ECCENTRIC ASSEMBLY ……………………………………….

23

REDUCER ASSEMBLY ……………………………………………

25

GEAR SHAFT ASSEMBLY…………………………………………

26

FLUID CYLINGDER & MANIFOLDS……………………………….. 27 STEEL-FITTED CENTER GUIDED VALVE ……………………….. 28 PLUNGER ASSEMBLY …………………………………………….. 29 LUBRICATING ASSEMBLY…………………………………… 30

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

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FRAME & MISCELLANEOUS PARTS No.

Name of Part

Qty.

Drawing No.

1

BEARING CAP

1

ZB-01Y-20

2

Wire

1

3

BOLT

8

ZB-01Y-35

4

NUT

12

ZB-01Y-23

5

WASHER-LOCK

24

GB93-27

6

STUD

10

ZB-01Y-22

7

STUD

2

ZB-01Y-38

8

BEARING SEAT

1

ZB-01Y-24

9

O-RING

2

GB34525.1-425X7

10

FRAME

1

ZB-01Y-04

11

AIR FILTER

1

C-M33X2

12

COVER

1

ZB-01Y-01

13

GASKET

2

ZB-01Y-02

14

UP COVER

1

ZB-01Y-17

15

GASKET

2

ZB-01Y-40

16

SIDE WINDOW PLATE

2

ZB-01Y-39

17

BEARING SEAT

1

ZB-01Y-30

18

BOLT

12

ZB-01Y-31

19

GASKET

1

ZB-01Y-33

20

BEARING CAP

1

ZB-01Y-32

21

WASHER-LOCK

8

GB93-14

22

BOLT

8

ZB-01Y-21

23

O-RING

1

GB34525.1-23.6X3.55

24

GASKET

1

ZB-01Y-37

25

MANDREL

1

ZB-01Y-36

26

BOLT

64

ZB-01Y-03

22

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

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ECCENTRIC ASSEMBLY No.

Name of Part

Qty.

Drawing No.

1

SPRING RING

1

GB894.1-95

2

BEARING ROLLER

1

ZB-02Y-19

3

SPRING RING

1

GB893.1-170

4

WIRE

1

5

BOLT

30

ZB-01Y-35

6

PLATE-RETAINER

2

ZB-01Y-34

7

GEAR

1

ZB-02Y-02

8

SLEEVE-RETAINER

1

ZB-01Y-19

9

BEARING ROLLNER

1

ZB-01Y-42

10

NUT

16

ZB-01Y-28

11

PLATE-RETAINER

16

ZB-01Y-26

12

WASHER-LOCK

16

GB93-14

13

BOLT

16

ZB-01Y-27

14

BEARING-ROLLER

2

ZB-01Y-43

15

KEY

1

GB45x260

16

ECCENTRIC

1

ZB-01Y-18

17

BEARING-ROLLER

1

ZB-01Y-44

18

CONNECTING ROD

3

ZB-01Y-05

19

PIN

6

GB119-12X26

20

BOLT

24

ZB-01Y-07

21

WASHER-LOCK

24

GB93-16

22

CONNECTING ROD SLEEVE

3

ZB-01Y-29

23

SCREW

12

GB73-16X60

24

CONNECTING ROD SMALL END SLEEVE

3

ZB-01Y-10

25

SPRING RING

6

GB893.1-120

26

PIN-CROSSHEAD

3

ZB-01Y-12

27

CROSSHEAD

3

ZB-01Y-08

28

ROD-EXTENSION

3

ZB-01Y-14

29

BOLT

12

ZB-01Y-13

30

GASKET

3

ZB-01Y-16

31

YX SEAL RING

6

JB/ZQ4265-90

32

HEAD-OIL STOP

3

ZB-01Y-15

33

SCREW

12

ZB-01Y-43

34

BOLT

6

ZB-03Y-15-01

35

WASHER-LOCK

6

GB93-14

36

COUPLING-PLUNGER

3

ZB-03Y-15

24

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REDUCER ASSEMBLY

No.

Name of Part

Qty.

Drawing No.

1

BOLT

45

ZB-02Y-04

2

WASHER0LOCK

45

GB93-16

3

O-RING

1

GB3452.1-212X7

4

PIN

3

GB119-16X35

5

REDUCER BODY

1

ZB-02Y-12

6

GASKET

1

ZB-02Y-11

7

GASKET

1

ZB-02Y-13

8

BOLT

16

ZB-02Y-05

9

WASHER-LOCK

16

GB93-10

10

BEARING CAP

1

ZB-02Y-06

11

GASKET

2

ZB-02Y-07

12

BEARING SEAT

1

ZB-02Y-03

13

O-RING

2

GB3452.1-243X7

14

BEARING SEAT

1

ZB-02Y-14

15

BEARING CAP

1

ZB-02Y-15

25

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

GEAR SHAFT ASSEMBLY

No.

Name of Part

Qty.

Drawing No.

1

OIL PLATE

1

ZB-02Y-08

2

BAFFLE PLATE

1

ZB-02Y-09

3

BEARING-ROLLER

2

ZB-02Y-18

4

KEY

1

ZB-02Y-17

5

GEAR SHAFT

1

ZB-02Y-01

6

PLATE-RETAINER

1

ZB-02Y-16

7

BOLT

4

ZB-01Y-35

8

WIRE

1

26

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

FLUID CYLINGDER & MANIFOLDS

No.

Name of Part

Qty.

Drawing No.

1

NUT

12

ZB-03Y-14

2

WASHER-LOCK

12

GB93-39

3

STUD

12

ZB-03Y-13

4

FLUID CYLINDER ASSEMBLY

1

ZB-03Y-02

5

LOCK-COVER,Valve

6

ZB-03Y-04

6

COVER-VALVE

3

ZB-03Y-03

7

O-RING

12

GB3452.1-115X5.3

8

STELL-FITTED CENTER GUIDED VALVE, See Page 9

6

ZB-03Y-05/ 06/ 07/ 10

9

SPRING SEAT

3

ZB-03Y-09

10

COVER-VALVE

3

ZB-03Y-08

11

BOLT

16

ZB-03Y-12-06

12

NUT

16

ZB-03Y-12-07

13

O-RING

3

GB3452.1-140X5.3

14

MANIFOLD-SUCTION ASSY.

1

ZB-03Y-12

15

BOLT

12

ZB-03Y-11

16

WASHER-LOCK

12

GB93-20

27

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

STEEL-FITTED CENTER GUIDED VALVE

No.

Name of Part

Qty.

Drawing No.

1

DISCHARGE SPRING

3

ZB-03Y-05

2

SUCTION SPRING

3

ZB-03Y-10

3

LOCK NUT

6

ZB-03Y-06-01

4

INSERT

6

ZB-03Y-06-02

5

VALVE-BODY

6

ZB-03Y-06-03

6

SEAT-VALVE

6

ZB-03Y-07

7

O-RING

6

GB3452.1-97.5X5.3

28

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

PLUNGER ASSEMBLY

No.

Name of Part

Qty.

Drawing No.

1

PLUNGER

3

ZB-03Y-01-01

2

ADJUST MUT

3

ZB-03Y-01-02

3

LINER

3

ZB-03Y-01-05

4

O-RING

3

GB3452.1-132X2.65

5

GASKET

3

ZB-03Y-01-03

6

OIL RING

3

ZB-03Y-01-04

7

GUIDE SLEEVE

3

ZB-03Y-01-06

8

STUFFING

15

ZB-03Y-01-07

9

CAULKING RING

3

ZB-03Y-01-08

10

OIL RING

3

GB3452.1-150X5.3

11

SUPPORT RING

3

ZB-03Y-01-09

12

SEAL GASKET

3

GB3452.1-122X5.3

29

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LUBRICATING ASSEMBLY

INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

30

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

LUBRICAT ING ASSEMBLY No.

Name of Part

Qty.

Drawing No.

1

BASE

1

ZB-04Y-01

2

GASKET

1

ZB-04Y-03

3

COVER

1

ZB-04Y-02

4

BOLT

32

ZB-04Y-04

5

OIL LEVEL SCALE

1

ZB-04Y-41

6

AIR FILTER

1

EF4-50

7

HYDRAULIC HOSE ASSEMBLY

1

D-16X1W-1100

8

FITTING

1

ZB-04Y-13

9

PRESSURE GAUGE

1

YTN-60

10

HYDRAULIC HOSE ASSEMBLY

1

D-16X1W-430

11

FITTING

1

ZB-04Y-40

12

PLATE

1

ZB-04Y-17

13

GASKET

1

ZB-04Y-18

14

DISTRIBUTOR

1

ZB-04Y-39

15

COPPER TUBE,TO LOWER GUIDE

3

GB1527-0 6X1X600

16

FITTING

16

ZB-04Y-14

17

NUT

16

ZB-04Y-15

18

TUBE BUSH

16

ZB-04Y-16

19

COPPER TUBE,TO LOWER GUIDE

3

GB1527-0 6X1X240

20

OIL PIPE ASSY. ,To CrankShaft Bearing

2

ZB-04Y-54

21

TEE

1

ZB-04Y-47

22

COPPER TUBE,TO CRANKSHAFT BEARING

1

GB1527-0 6X1X450

23

FITTING

1

ZB-04Y-45

24

NUT

2

ZB-04Y-11

25

TUBE BUSH

2

ZB-04Y-12

26

COPPER TUBE

1

GB1527-0 12X1X1150

27

FITTING

1

ZB-04Y-10

28

OVERFLOW VALVE

1

YYFJ-L20

29

CLAMP

1

ZB-04Y-48

30

SCREW

1

GB65-M6X10

31

CLAMP SEAT

1

ZB-04Y-49

32

FITTING

1

ZB-04Y-44

33

FITTING

1

ZB-04Y-50

34

NOZZLE

1

ZB-04Y-34

35

HYDRAULIC HOSE ASSEMBLY

1

D-13X1W

36

TEE

1

ZB-04Y-29

37

CONNECTING PIPE

1

ZB-04Y-09

38

BOLT

8

ZB-04Y-08

39

COUPLING

2

ZB-04Y-28

40

GASKET

2

ZB-04Y-27

41

FLUID END OIL PUMP

1

CB-FA10-FL

31

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INSTRUCTION MANUAL FOR ZB-400II PLUNGER PUMP

SPRING GASKET

4

43

BOLT

4

ZB-04Y-30

44

HYDRAULIC HOSE ASSEMBLY

1

D-10X1W-1400

45

FITTING

1

ZB-04Y-33

46

0 RING

2

GB3452.1-30X2.65

42

47

0 RING

2

GB3452.1-36.5X2.65

48

FITTING

1

ZB-04Y-26

49

FITTING

1

ZB-04Y-32

50

HYDRAULIC HOSE ASSEMBLY

1

D-13X1W-1450

51

POWER END OIL PUMP

52

FLANGE

2

ZB-04Y-05

53

SEAL

2

ZB-04Y-07

54

SEAL FLANGE

2

ZB-04Y-06

55

CONNECTING PIPE

1

ZB-04Y-42

56

FITTING

1

ZB-04Y-51

57

CONNECTING PIPE

1

ZB-04Y-43

58

HYDRAULIC HOSE ASSEMBLY

1

D-25X1W-550

59

COVER

1

ZB-04Y-24

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CBF-E450P

60

GASKET

1

ZB-04Y-25

61

OIL TANK

1

ZB-04Y-22

62

FITTING

1

ZB-04Y-35

63

FITTING

1

ZB-04Y-23

64

0 RING

1

GB3452.1-45X2.65

65

OIL FILTER

1

CXL-100X80

66

SCREW

4

GB70-M8X25

67

CONNECTING PIPE

1

ZB-04Y-21

68

FITTING

1

ZB-04Y-19

69

FITTING

6

ZB-04Y-20

70

HYDRAULIC HOSE ASSEMBLY,To Plunger Assembly

1

D-6X1W-800

71

HYDRAULIC HOSE ASSEMBLY,To Plunger Assembly

1

D-6X1W-550

72

HYDRAULIC HOSE ASSEMBLY,To Plunger Assembly

1

D-6X1W-300

73

BOLT

4

ZB-04Y-38

74

DISTRIBUTOR

1

ZB-04Y-37

75

GASKET

1

ZB-04Y-36

76

CLAMP ASSY.

2

ZB-04Y-52

77

CLAMP ASSY.

3

ZB-04Y-53

78

SCREW PLUG

2

ZB-04Y-31

32

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