Parts for 3NB1600 Mud Pump

1

Slush pump

107.11.00

High-strength alloy steel (main body) + gray cast iron (auxiliary structure)

1. Cyclic pressure impact from high-density drilling fluid; 2. Wear of internal pinion shaft/crosshead components; 3. Corrosion from acidic/alkaline drilling media.

1. Conduct pressure tests per GB/T 5657-2013; 2. Use compatible drilling fluid to avoid corrosion; 3. Inspect core assemblies quarterly for wear.

2

Pinion shaft & crosshead assy

107.11.10.00

Alloy steel (40Cr, quenched & tempered for shaft; 45# steel for crosshead)

1. High torque impact during startup/shutdown; 2. Friction wear between shaft and bush; 3. Misalignment causing uneven stress distribution.

1. Verify coaxiality before installation (tolerance ≤ 0.02mm); 2. Maintain continuous lubrication to reduce friction; 3. Avoid sudden overload to prevent deformation.

3

Crosshead center & LH

—

45# steel (carburized and quenched, surface hardness HRC 58-62)

1. Wear from high-frequency reciprocating motion; 2. Lack of lubrication causing metal-to-metal friction; 3. Impact damage from improper assembly.

1. Ensure proper lubrication before operation; 2. Check fit clearance (0.03-0.05mm) during assembly; 3. Replace if wear exceeds GB/T 3811-2008 standards.

4

Crosshead Left

107.11.20.33

45# steel (carburized and quenched, surface hardness HRC 58-62)

1. Reciprocating friction leading to surface wear; 2. Debris contamination causing abrasive wear; 3. Stress concentration at edge contact points.

1. Clean assembly area to avoid debris; 2. Inspect surface roughness (Ra ≤ 0.8μm) monthly; 3. Use high-temperature resistant lubricant (operating temp ≤ 100°C).

5

Crosshead right

—

45# steel (carburized and quenched, surface hardness HRC 58-62)

1. Wear from high-frequency reciprocating motion; 2. Misalignment causing uneven stress; 3. Corrosion from lubricant contamination.

1. Align with crosshead center during installation; 2. Replace lubricant regularly to avoid contamination; 3. Check for deformation monthly via dial gauge.

6

Crosshead center & R.H

107.11.20.34

45# steel (carburized and quenched, surface hardness HRC 58-62)

1. Abrasive wear from debris intrusion; 2. Fatigue damage from long-term reciprocation; 3. Lack of lubrication causing seizing.

1. Install a high-precision filter to prevent debris; 2. Conduct non-destructive testing quarterly; 3. Ensure lubricant flows to all contact surfaces.

7

Crosshead pin

107.11.20.37

Alloy steel (40CrNiMoV, tensile strength ≥ 1080MPa)

1. Shear stress from reciprocating load; 2. Wear at contact points with crosshead; 3. Corrosion from humid drilling environments.

1. Check shear strength regularly; 2. Apply anti-rust coating (zinc-nickel alloy) to exposed surfaces; 3. Ensure proper fit with pin retainer.

8

Shaft

107.11.10.05

Alloy steel (40Cr, quenched & tempered, hardness HRC 28-32)

1. Fatigue cracking from long-term torque; 2. Journal wear due to lubricant contamination; 3. Misalignment causing uneven wear.

1. Replace lubricant every 800 working hours; 2. Inspect journal surface for wear (allowable wear ≤ 0.02mm); 3. Verify coaxiality during maintenance.

9

Righ Hand gear

107.11.10.07

Alloy steel (20CrMnTi, carburized, tooth surface HRC 60-64)

1. Gear tooth wear from meshing friction; 2. Impact loading during startup; 3. Lubricant deficiency causing tooth scuffing.

1. Ensure proper gear meshing clearance (0.15-0.20mm); 2. Use extreme pressure lubricant; 3. Inspect tooth surface for pitting monthly.

10

Left-hand gear

107.11.10.08

Alloy steel (20CrMnTi, carburized, tooth surface HRC 60-64)

1. Tooth wear from continuous meshing; 2. Debris intrusion causing abrasive damage; 3. Fatigue failure from cyclic load.

1. Clean gear box regularly; 2. Replace if tooth wear exceeds 10% of tooth thickness; 3. Maintain stable operating speed (±5% of rated speed).

1

Bearing

154942Q (Ø209*282*236)

High-carbon chromium bearing steel (GCr15, hardness HRC 61-65)

1. Lubricant contamination causing abrasive wear; 2. Overheating from insufficient lubrication; 3. Misalignment leading to uneven load distribution.

1. Use clean, compatible lubricant; 2. Monitor operating temperature (not exceeding 80°C); 3. Ensure proper press-fit installation (interference 0.01-0.03mm).

2

Bearing

32848HU (240x390x108)

High-carbon chromium bearing steel (GCr15, hardness HRC 61-65)

1. Fatigue damage from long-term heavy load; 2. Debris intrusion causing raceway wear; 3. Corrosion from humid on-site environments.

1. Install a dust cover to prevent debris; 2. Conduct vibration analysis monthly (allowable vibration ≤ 4.5mm/s); 3. Store in a dry, clean environment before use.

3

Bearing cage

107.11.10.03

Engineering plastic (PA66+GF30) + steel reinforcement

1. Wear from contact with bearing rollers; 2. High temperature causing material aging; 3. Impact damage during disassembly.

1. Avoid overheating during operation; 2. Disassemble gently with specialized tools; 3. Replace if cracks or deformation occur.

4

Bearing cover

107.11.10.01

Carbon steel (Q235B, surface galvanized)

1. Corrosion from on-site environment; 2. Deformation from uneven bolt torque; 3. Wear from bearing rotation.

1. Tighten bolts evenly per torque standard (45-50N·m); 2. Inspect for cracks monthly; 3. Touch up anti-rust coating annually.

1

Oil seal

D7-1-67 (260*300x20)

Nitrile rubber (NBR 70) + steel skeleton, lip coated with PTFE

1. Aging from high temperature and lubricant; 2. Wear from shaft rotation; 3. Debris causing lip damage.

1. Replace every 600 working hours; 2. Clean shaft surface (Ra ≤ 0.4μm) before installation; 3. Avoid sharp edges contacting the seal lip.

2

Seal

—

Fluororubber (FKM, temperature resistance -20°C to 200°C)

1. Chemical corrosion from lubricant additives; 2. Compression deformation from over-tightening; 3. High temperature causing material degradation.

1. Ensure proper compression (compression ratio 15-20%); 2. Use compatible lubricant; 3. Avoid operating beyond 120°C.

3

Gasket

107.11.10.M (51)

Asbestos-free rubber (NBR + aramid fiber, shore hardness 70±5)

1. High temperature aging; 2. Pressure damage from over-tightening; 3. Oil corrosion leading to brittleness.

1. Do not over-tighten bolts; 2. Replace after disassembly; 3. Avoid contact with high-temperature components (≥120°C).

4

Gasket

107.11.10.09

Asbestos-free rubber (NBR + aramid fiber, shore hardness 70±5)

1. Vibration causing edge wear; 2. Moisture leading to softening; 3. Improper storage causing deformation.

1. Store in sealed packaging; 2. Check for deformation before installation; 3. Ensure mating surfaces are clean.

5

Gasket

107.11.10.10

Asbestos-free rubber (NBR + aramid fiber, shore hardness 70±5)

1. Chemical corrosion from drilling fluid; 2. Compression fatigue from long-term use; 3. Installation misalignment causing leakage.

1. Clean mating surfaces before installation; 2. Replace every 600 working hours; 3. Avoid contact with drilling fluid.

6

Gasket

107.11.10.11

Asbestos-free rubber (NBR + aramid fiber, shore hardness 70±5)

1. Aging from long-term storage; 2. Damage during installation; 3. Compression fatigue under high pressure.

1. Use fresh gaskets for installation; 2. Handle gently to avoid tearing; 3. Ensure proper fit with mating components.

7

Gasket

107.11.10.12

Asbestos-free rubber (NBR + aramid fiber, shore hardness 70±5)

1. Wear from vibration; 2. Corrosion from lubricant; 3. Improper installation causing uneven compression.

1. Install evenly to ensure uniform compression; 2. Replace lubricant regularly; 3. Check for leakage after installation.

8

Oil conductor

107.11.20.38 (Ø20x2 L=25)

Seamless steel tube (20#, wall thickness 2mm, surface galvanized)

1. Blockage from oil impurities; 2. Wear from vibration friction; 3. Corrosion from lubricant additives.

1. Flush regularly to remove impurities; 2. Secure to reduce vibration; 3. Replace if blockage or corrosion occurs.

9

Oil box

107.11.12.M

Galvanized steel (Q235B, thickness 3mm, anti-rust coating)

1. Corrosion from moisture in oil; 2. Welding seam leakage from vibration; 3. Internal scaling affecting oil quality.

1. Keep sealed to prevent moisture intrusion; 2. Clean internal scaling annually; 3. Inspect welding seams for cracks.

1

Screw

107.11.20.43 (M20x55)

Alloy steel (8.8 grade, surface zinc-plated)

1. Thread wear from frequent disassembly; 2. Fatigue failure from long-term vibration; 3. Corrosion from on-site environment.

1. Torque to standard values (65-70N·m) during installation; 2. Apply thread lock to prevent loosening; 3. Inspect threads for damage before use.

2

Screw

GB32.1-88 (M16x30)

Carbon steel (8.8 grade, surface zinc-plated)

1. Vibration causing loosening and thread wear; 2. Corrosion from humid environment; 3. Over-tightening causing shank deformation.

1. Use a torque wrench for installation (40-45N·m); 2. Apply anti-rust coating; 3. Check tightness weekly.

3

Bolt

GB5783-86 (M20x50)

Alloy steel (8.8 grade, surface zinc-plated)

1. Fatigue fracture from cyclic load; 2. Thread corrosion; 3. Improper torque leading to damage.

1. Torque to manufacturer’s standards (60-65N·m); 2. Replace after one fatigue cycle; 3. Use lock washers to prevent loosening.

4

Washer

GB93-87 (20)

Carbon steel (spring steel, surface zinc-plated, hardness HRC 42-48)

1. Elastic fatigue losing locking function; 2. Corrosion causing breakage; 3. Deformation from over-tightening.

1. Replace with bolts; 2. Do not reuse deformed washers; 3. Ensure compatibility with bolt size.

5

Pin retainer

107.11.20.44

Carbon steel (Q235B, surface galvanized)

1. Wear from contact with crosshead pin; 2. Corrosion from lubricant; 3. Deformation from improper installation.

1. Ensure proper fit with crosshead pin; 2. Apply anti-corrosion coating; 3. Inspect for wear during maintenance.

6

Outer retainer

107.11.20.36

Carbon steel (Q235B, surface galvanized)

1. Wear from bearing rotation; 2. Corrosion from on-site environment; 3. Impact damage during disassembly.

1. Install tightly to fix the bearing; 2. Apply anti-rust paint; 3. Disassemble gently to avoid damage.

7

Inside retainer

107.11.20.35

Carbon steel (Q235B, surface galvanized)

1. Wear from bearing movement; 2. Contamination causing abrasive wear; 3. Deformation from uneven pressure.

1. Clean before installation; 2. Ensure uniform pressure during assembly; 3. Replace if deformed.

8

Bush

107.11.10.02

Copper alloy (ZCuSn10Pb1, hardness HB 80-90)

1. Wear from shaft rotation; 2. Lack of lubrication causing metal-to-metal friction; 3. Abrasive wear from debris.

1. Ensure sufficient lubrication; 2. Clean assembly area to avoid debris; 3. Replace if wear exceeds 0.5mm.

9

key

107.11.10.06

45# steel (quenched & tempered, hardness HRC 30-35)

1. Shear stress from torque transmission; 2. Wear from keyway contact; 3. Impact damage during assembly.

1. Ensure proper fit with keyway (interference 0.01-0.02mm); 2. Avoid excessive torque during installation; 3. Inspect for shear cracks regularly.

10

Key

107.11.10.13 (50.8x38.1x385)

45# steel (quenched & tempered, hardness HRC 30-35)

1. Wear from reciprocating torque; 2. Keyway deformation causing uneven stress; 3. Corrosion from lubricant contamination.

1. Check keyway for deformation before installation; 2. Use clean lubricant; 3. Replace if excessive wear occurs.

11

Wire

Ø2 L=2500

Stainless steel (304, tensile strength ≥ 520MPa)

1. Fatigue breakage from repeated bending; 2. Corrosion from humid environment; 3. Wear from friction with other components.

1. Avoid excessive bending during installation; 2. Store in a dry place; 3. Replace if signs of fatigue appear.

12

Wire

Ø1.2 L=1500

Stainless steel (304, tensile strength ≥ 520MPa)

1. Wear from friction; 2. Breakage from overloading; 3. Corrosion from on-site chemicals.

1. Do not exceed load capacity (≤ 2.5kN); 2. Keep away from chemicals; 3. Inspect for wear before use.

13

Shim for pin retainer

107.11.20.39

Carbon steel (Q235B, thickness 0.1-0.3mm)

1. Wear from contact with pin retainer; 2. Deformation from pressure; 3. Corrosion from lubricant.

1. Select proper thickness for fit; 2. Ensure even pressure during installation; 3. Replace if deformed or worn.

14

Shim for pin retainer

107.11.20.40

Carbon steel (Q235B, thickness 0.1-0.3mm)

1. Abrasive wear from debris; 2. Fatigue deformation from long-term pressure; 3. Corrosion from humid environment.

1. Clean before installation; 2. Replace if thickness deviates from standard; 3. Store in a clean, dry place.

15

Shim for pin retainer

107.11.20.41

Carbon steel (Q235B, thickness 0.1-0.3mm)

1. Wear from pin retainer movement; 2. Pressure causing material thinning; 3. Corrosion from lubricant additives.

1. Check thickness regularly; 2. Replace with matching specification; 3. Avoid over-tightening to prevent damage.

16

Shim for pin retainer

107.11.20.42

Carbon steel (Q235B, thickness 0.1-0.3mm)

1. Deformation from uneven pressure; 2. Wear from long-term use; 3. Corrosion from on-site environment.

1. Install evenly to ensure uniform pressure; 2. Apply anti-corrosion coating; 3. Replace if deformation occurs.

1

What lubricant is suitable for 3NB1600 pinion shaft and crosshead assemblies?

Use ISO VG 68 extreme pressure industrial gear oil, compliant with GB/T 3141-2019. It resists high temperature (≤120°C) and heavy load, reduces friction between shafts/bearings/bushes, and extends component service life by 30%.

2

How often should I replace the oil seal and gaskets for this assembly?

Replace the oil seal every 600 working hours; replace gaskets after each disassembly or every 800 working hours. Regular replacement prevents lubricant leakage and impurity intrusion, avoiding costly core component damage.

3

How to prevent crosshead pin and key shear failure in the 3NB1600?

Ensure proper fit between crosshead pin/retainer and key/keyway; avoid sudden overload during startup; torque fasteners to standard values; conduct monthly inspections for wear or stress cracks; use clean lubricant to reduce friction.