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CHANGING DISCHARGE MODULE

1. TOOLS AND EQUIPMENT

SLEDGE HAMMER
HAMMER WRENCHES AS REQUIRED
TORQUE WRENCH 500 FT LB
4 X MULTIPLIER FOR TORQUE WRENCH
SOCKETS AS REQUIRED
RATCHET AND FLEX BAR
COMBINATION WRENCHES AS REQUIRED
2ea. 1 TON CHAIN HOISTS
3ea. 4 1/2 TON SHACKLES
2ea. WORK CHAINS WITH HOOKS
RAGS, WD-40, NEVER SEIZE AND GREASE
IMPACT WRENCH

NEW PUMP PARTS - (12-P-160)

DISCHARGE MODULE
VALVE SEAT AND SPRING
VALVE AND INSERT
VALVE COVER SEAL
4 ea # 1292175 BACKUP RING
2 ea # 1292252 DISCHARGE CONNECTOR
2 ea # 1292253 DISCHARGE CONNECTOR ADAPTOR
2 ea # 1292257 MODULE SEAL
1 ea # 1292258 DISCHARGE SPACER SEAL
1 ea # 1292262 STUDDED SPACER
1 ea # 1262266 WEAR PLATE
2 ea # 2410031-433 RECTANGULAR PACKING
2 ea # 2410031-437 RECTANGULAR PACKING
16 ea # 7000307-11 HEX HEAD CAP SCREWS
8 ea # 7006685 HEX SOCKET HEAD SCREW
2 ea R - 44 RING GASKET

NOTE:

BEFORE COMMENCING THIS JOB IT IS NECESSARY TO HAVE ON HAND, A

MINIMUM OF THE SPARE PARTS LISTED ABOVE, FOR THE CHANGE OUT OF 1
MODULE, IN CASE THE DISCHARGE CONNECTORS HAVE TO BE CUT OUT, OR THE
SPACER FLANGE CANNOT BE IMMEDIATELY REMOVED FROM THE WORN OUTER
MODULES. PHYSICALLY CHECK THAT ALL THESE PARTS ARE AVAILABLE BEFORE
PROCEEDING.

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CHANGING DISCHARGE MODULE
2. SAFETY INFORMATION AND PRECAUTIONS
PERFORM SAFETY AND ISOLATION PROCEDURES AS PER SECTION 2: CHAPTER
02, AND REFER TO SECTION 2: CHAPTER 08.
FOR SUCTION MODULE REMOVAL.

3. PROCEDURE

3.1 FOR REMOVAL

1. REMOVE THE PISTON AS PER SECTION 2: CHAPTER 06.

2. REMOVE THE LINER AS PER SECTION 2: CHAPTER 07.

3. REMOVE THE SUCTION MODULE AS PER SECTION 2: CHAPTER 08.

4. REMOVE 6 ea 1 1/8" NUTS AROUND THE LINER BUSHING AND PULL THE
LINER BUSHING.

5. REMOVE THE DISCHARGE CONNECTOR SCREWS AND PUSH THE

DISCHARGE CONNECTORS INTO THE CYLINDER BORES TO PROVIDE
CLEARANCE, USING THE JACKING BOLTS. IF THIS DOES NOT WORK, DUE
TO A BUILD UP OF SOLIDS AND OR CORROSION IN THE RECESSES BEHIND
THE DISCHARGE CONNECTORS, THEN IT WILL BE NECESSARY TO CUT
OUT THE CONNECTORS WITH A CUTTING TORCH. THE NECESSARY "HOT
WORK PERMIT" SHOULD BE OBTAINED AND THE TOOLPUSHER SHOULD
BE SUMMONED TO BE PRESENT. NEW CONNECTORS AND SEALS SHOULD
BE ON HAND FOR THIS EVENTUALITY.

NOTE: IF EITHER OF THE OUTER DISCHARGE MODULES

ARE TO BE REMOVED, IT IS NECESSARY TO REMOVE EITHER THE
PULSATION DAMPENER ASSEMBLY OR DISCHARGE / BLEED-OFF
ASSEMBLY, FROM THE SIDE OF THE MODULE, BY BREAKING OFF
THE FLANGE AT THE DISCHARGE OUTLET.

6. REMOVE THE NUTS HOLDING THE DISCHARGE MODULE TO THE FRAME,

AND SLIDE IT OUT OVER THE SUCTION MANIFOLD, USING THE CHAIN
HOISTS BY LIFTING ON CAP.

7. REMOVE THE MODULE CONNECTOR AND ADAPTOR AND THOROUGHLY

CLEAN THE CONNECTOR BORES OF THE NEW MODULES TO BE INSTALLED.

NOTE: IF THE ADAPTERS CANNOT BE REMOVED FROM

THE OLD MODULE, THEN USE NEW ONES, WHICH SHOULD BE
ON HAND, IN THE REPLACEMENT MODULE.

3.2 FOR INSTALLATION

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CHANGING DISCHARGE MODULE
1. REPLACE THE SEALS AND THOROUGHLY GREASE THE CONNECTOR
AND ADAPTOR.

2. SLIDE THE CONNECTOR INTO THE OUTER MODULE AND ADAPTOR

INTO THE CENTER MODULE.

3. PULL SEAT AND REMOVE STUDS AND THREADED RING FROM OLD
MODULE.

4. CLEAN DISCHARGE MODULE SEAL FACES.

5. INSTALL NEW LIGHTLY GREASED SEAL INTO COUNTER BORE OF

DISCHARGE MODULE AND CHECK CONDITION OF WEAR PLATE.

NOTE: CHANGE THE WEAR PLATE IF IT IS WASHED IN THE SEAL AREA.

6. INSTALL THE NEW, PRE-CLEANED DISCHARGE MODULE, USING LIFTING

PADEYES ON TWO STUDS TO LIFT WITH.

7. WITH NEW MODULE IN PLACE, CHECK THAT ALL SEALS ARE STILL IN
PLACE AND NOT DAMAGED OR ROLLED.

8. TIGHTEN NUTS FINGER TIGHT.

(DO NOT MAKE TOO TIGHT AT THIS POINT).

9. INSTALL SUCTION MODULE AS PER SECTION 2: CHAPTER 08.

10. INSTALL WEAR PLATE. LINER PILOT BUSHING AND LINER

(SECTION 2: CHAPTER 07).

11. TIGHTEN THE DISCHARGE MODULE TO THE FRAME FACE, TORQUING THE
NUTS TO 1460 FT LB.

12. MOVE THE DRILLED FLANGE CONNECTOR, IN THE OUTSIDE CYLINDER

MODULE, AGAINST THE CENTER MODULE, TRAPPING THE SEAL IN THE
GROOVE OF THE CONNECTOR FLANGE, NEXT TO THE FACE OF THE
ADAPTOR IN THE CENTER MODULE.

13. TIGHTEN IN PLACE USING THE SEGMENTAL BACK UP RING UNDER THE CAP
SCREWS, USE APPROXIMATELY 75 FT LB TORQUE ON THESE CAP SCREWS.

NOTE: IF EITHER OF THE OUTER DISCHARGE MODULES

HAVE TO BE CHANGED, IT WILL BE NECESSARY TO REMOVE THE
DISCHARGE OUTLET FLANGE AND SPACER FLANGE FROM THE
UNSERVICEABLE MODULE, AND THEN INSTALL THEM ONTO THE
NEW MODULE, USING A NEW DISCHARGE SPACER SEAL. THEN
REPLACE EITHER THE PULSATION DAMPENER OR DISCHARGE /
BLEED-OFF ASSEMBLY USING A NEW R-44 RING GASKET.

14. CLEAN AND INSTALL NEW VALVE, SEAT, VALVE AND SPRING AS PER

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CHANGING DISCHARGE MODULE
SECTION 2: CHAPTER 05.

15. INSTALL A NEW VALVE COVER SEAL.

16. TRANSFER THREADED RING AND VALVE CAP TO NEW MODULE.

NOTE: IN THE SITUATION WHERE, WHEN REMOVING THE

CENTER DISCHARGE MODULE, IT IS NOT POSSIBLE TO SLIDE THE
CONNECTOR INTO THE CYLINDER BORE, DUE TO SEIZING, IT MAY
BE NECESSARY TO REMOVE EITHER OF THE OUTER DISCHARGE
MODULES TO FACILITATE EASE OF REMOVAL OF THE CENTER
MODULE.

3.3 COMPLETION
RESTORE THE PUMP TO OPERATING MODE AS PER PROCEDURES SET OUT IN
SECTION 2: CHAPTER 2:

3.4 CHECKS
PRESSURE THE PUMP TO 25,000 KPA AND OBSERVE ALL MODULE PRESSURE
CONNECTIONS FOR LEAKS.

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