Brahma Pumps Maintanance
Brahma Pumps Maintanance
Brahma Pumps Maintanance
JKS BOYLES pumps operate well in either direction of rotation. The main bearings are designed to withstand any loads that may be
imposed on the shaft by a flexible coupling, V-belt or roller chain drive. Solid couplings are not acceptable.
LUBRICATION
New pumps are lubricated prior to testing and shipping. Relubricate according to instructions on the pump body.
COLD WEATHER
Freezing can damage your pump. Pour anti-freeze into pump inlet and turn pump a few revolutions to circu1ate it. Always turn pump by
hand before operating in cold weather to check for ice behind pistons.
CAUTION: If pump is frozen, do not pour hot water over the pump. Sudden temperature fluctuations will cause further damage.
STORAGE
MATERIAL HANDLED
Pumps are not recommended for handling fluids in excess of 150º Fahrenheit. Aluminium pump models are not recommended for, use
with caustics. When pumping caustic solutions cast iron pumps are recommended. Generally, when in doubt, check with pump
manufacturer and chemical manufacturer to ascertain compatibility of chemical and pump materials.
Solid particles larger than 1/16 inch can hamper valve action; larger than 1/4 inch can lodge in pump passage ways. A suction strainer will
prevent coarse particles from entering pump.
Sudden temperature fluctuations greater than 100 Fahrenheit degrees in fluid being pumped will crack ceramic liners
LEAKAGE
Heavy-duty piston cups may leak during first few hours of operation until properly seated. If available, use Teflon lubricant when
installing new cups. Otherwise keep cylinders and piston components clean and free of grease or other deposits. (Remove excess grease
from front bearing cavity). Pump cups running on hot water will leak if subjected to cold water, but will dry up again when returned to
hot operation
INSTALLATION OF PUMP
Cavitation due to undersized or long suction lines is a cause of premature pump failure. If the new pump is noisy or down in volume, it
may be cavitating. JKS BOYLES staff will be pleased to assist you in problems concerning pump installation.
FIG. 1
For domestic water supplies (typical arrangement fig 2) make certain that the volume is ample for the pump. About 10% reserve volume
at the pump inlet is recommended.
FIG. 2
Trouble Shooting
A. Decreased Delivery Accompanied By Rough Operation.
Possible Causes:
1. Air entering suction piping
2. Air leaking past piston cups
3. Pomp valve malfunction
4. Plugged or restricted pump suction passages
5. Plugged or constricted suction piping (suction valve not fully open)
6. Collapsed suction hose.
Checking Procedure:
1. Examine the valve seats for wear and pitting.
2. Arrange a barrel or tank and a hose from pump outlet or regulating relief valve by-pass outlet to collect the entire pump discharge.
Measure the time to collect a predetermined volume or, with the barrel or tank on a weigh scale, weigh the results of three or four
minutes of pumping. Comparing the measured flow in gallons per minute with the rated capacity for the pump speed, (see page 4
'Calculating Volume' in relation to pump speed) will show whether or not the discharge has actually decreased.
3. Examine the water in the barrel or tank for air bubbles while the pump is discharging. If no bubbles are seen and the discharge has
definitely decreased, look for plug-ups, worn valve seats or collapsed suction hose. If bubbles are seen, look for air leaks in the
suction piping or for air leaking past the piston cups. These leaks are hard to find because they are leaking 'in' rather than 'out',
however, if arrangements are made to put pressure into the suction piping or if new cups smooth out the pump operation, the
problem is solved.
B. Decreased Delivery Accompanied By Smooth Operation.
Possible Causes:
1. Worn Valve Seats.
2. Slipping belts
Checking Procedure:
1. Look for worn or pitted valve seats.
2. Measure clearance between outer surface of eccentric roller bearing and yoke pads with a feeler gauge. This should not exceed .010"
3. Measure pump speeds with a tachometer.
Corrective Action
1. Renew Worn Valve Seats.
2. Replace badly worn belts.
NOTE: Worn yoke pads will give very noisy operation. Depending on pump model, worn yokes or pads should be replaced.
C. Excessive Leakage.
2, 6 & 7. Tighten loose piston bolts, cylinder head bolts and valve caps.
Remove cylinder blocks or cylinder heads and examine ceramic liners for cracks.
NOTE: Excessive grease leakage results from bent or dented Nylos seals. Damaged seals should be replaced.
Checking Procedure
1) Measure crankshaft end play with a dial indicator, micrometer or feeler gauge. It should be set between .003 inches and .005 inches.
2) With end play corrected, turn crankshaft by hand and “feel” for rough main bearings. Check eccentric bearing wear by measuring side
play with a dial indicator, micrometer or feeler gauges. It should not exceed .005 inches
(Replace worn bearings)
Suction Pipe Sizing
Use the following formulas to solve for the maximum allowable mean velocity in the suction line - then from the velocity table choose a
pipe size in which the mean velocity will not exceed the calculated value.
Assuming that the fluid is water, solve for maximum allowable mean velocity, V, in the suction line as follows:
Select a pipe size from Table 3 to give a velocity less than or equal to the above calculated “v”. Suction lines larger than the pump inlet
may be required.
SEE EXAMPLES
TABLE 1 TABLE 2
WATER VAPOUR PRESSURE ATMOSPHERIC PRESSURE
TEMP. ABSOLUTE ALTITUDE ABSOLUTE
PRESSURE FT. (FT.) PRESSURE FT.
ºF WATER WATER
30 0 Sea Level 33
50 0 1000 31.8
70 1 1500 31.1
90 2 2000 30.5
110 3 4000 28.2
130 5.5 6000 26.2
150 8 8000 24.2
170 13.5 10000 22.4
190 23
210 34 * 1 ft. Deducted from normal values to
allow for deviations
TABLE 3
Mean Velocity Table
(Feet/sec.)
U.S. Inside Diameter of Suction Pipe (inches)
Gal/Min
Flow Rate ½ ¾ 1 1¼ 1½ 2 2½ 3
1 1.6 0.7 0.4 0.3 0.2 0.1 - -
2 3.3 1.4 0.8 0.5 0.4 0.2 0.1 0.1
3 4.9 2.2 1.2 0.8 0.5 0.3 0.2 0.1
4 6.5 2.9 1.6 1.0 0.7 0.4 0.3 0.2
5 8.2 3.6 2.0 1.3 0.9 0.5 0.3 0.2
6 9.8 4.3 2.4 1.6 1.1 0.6 0.4 0.3
7 11.4 5.1 2.9 1.8 1.3 0.7 0.5 0.3
8 13.1 5.8 3.3 2.1 1.4 0.8 0.5 0.4
9 14.7 6.5 3.7 2.3 1.6 0.9 0.6 0.4
10 16.3 7.2 4.1 2.6 1.8 1.0 0.7 0.5
11 17.9 8.0 4.5 2.9 2.0 1.1 0.7 0.5
12 19.6 8.7 4.9 3.1 2.2 1.2 0.8 0.5
13 21.2 9.4 5.3 3.4 2.4 1.3 0.8 0.6
14 22.8 10.1 5.7 3.6 2.5 1.4 0.9 0.6
15 24.5 10.9 6.1 3.9 2.7 1.5 1.0 0.7
16 11.6 6.5 4.2 2.9 1.6 1.0 0.7
17 12.3 6.9 4.4 3.1 1.7 1.1 0.8
18 13.1 7.3 4.7 3.3 1.8 1.2 0.8
19 13.8 7.7 5.0 3.4 1.9 1.2 0.9
20 14.5 8.2 5.2 3.6 2.0 1.3 0.9
21 15.2 8.6 5.5 3.8 2.1 1.3 1.0
22 16.0 9.0 5.7 4.0 2.2 1.4 1.0
23 16.8 9.4 6.0 4.2 2.3 1.4 1.0
24 17.4 9.8 6.3 4.4 2.4 1.5 1.1
25 18.1 10.4 6.6 4.5 2.5 1.6 1.1
26 18.9 10.6 6.8 4.7 2.6 1.7 1.2
27 19.6 11.0 7.0 4.9 2.8 1.8 1.2
28 20.3 11.4 7.3 5.1 2.9 1.8 1.3
29 21.0 11.8 7.6 5.3 3.0 1.9 1.3
30 21.8 12.2 7.8 5.4 3.1 2.0 1.4
Examples of Suction Pipe Sizing
Suction Line length should be as short as possible having the least number of fittings. If a shut-off valve is required in the line it should be
the gate type.
EXAMPLE NO. 1
EXAMPLE NO. 2
Note in Table 3 that velocity nearest to 2.09 at flow rate of 5 gpm appears in column headed 1" pipe and should be acceptable.
Pressure piping and/or hose, within practical limits, must be sized to handle the rated pump capacity without exceeding the maximum
pressure of the pump. (Use hose Suppliers Guide)
CALCULATING HORSEPOWER REQUIREMENTS FOR ALL PUMP MODELS USING THE FACTOR TABLE BELOW. (H.P.
= Factor 'F' X Actual Pump Speed X Pressure ÷ 33,000)
TABLE 5
FACTOR 'F' AT VARIOUS PRESSURES P.S.I.
PUMP MODEL 100- 160- 260- 360- 460- 560- 660- 760-
140 240 340 440 540 640 740 840
BRONC0 2 .30 .26 .24 .23 .21 .19 .17
BRONC0 8 .60 .52 .47 .42 .40 .35 .32
BRAHMA 12 1.68 1.51 1.40 1.29 1.19 1.11 1.04
BRAHMA 24 2.15 1.98 1.79 1.64 1.54 1.43 1.32
Factor ‘F' embodies load on the pump and friction loss including the friction loss of the V belt drive. The above table can be used for any
speed and pressure within range of the pump model.
Example of the use of the factors for calculating Horse power requirements:
EXAMPLE (Brahma 24 at 308 rpm and 760 psi) Factor ‘F' from above table at 760 psi = 1.32
Then 1.32 X 308 X 760 = 9.35
33,000
Crankshaft can be bumped out of pump body on a wood block, as shown above, after removal of the piston yokes, as follows;-
1) Yoke and piston assemblies of RP2-4 and Pinto Model pumps are removed together with the cylinder blocks. (6 capscrews in each
block to be removed)
2) All other pump models require removal of the cylinder heads to expose the piston bolts Loosen the piston bolts in order to free the
yokes. (see page 7)
3) Remove the Timken lockout and lock washer. (RP2-4 has solid set collar to be removed). Use Timken TNO6 & TNO8 Lock nut
wrenches.
Eccentric bearings and inner main bearings are removed, preferably on a hydraulic press, with minimum amount of tooling shown above.
(RP2-4 Model Pump requires conventional ball bearing or gear puller to remove bearings from pump body).
Depending on Pump Model, main bearings will be complete with integral seal or have separate NILOS metal seal. Metal seals may be
damaged in disassembly and must be replaced.
IMPORTANT INFORMATION RE: ECCENTRIC BEARINGS. For Brahma and Mustang Model pumps only. Make certain that
name and number of each bearing face up before pressing it on the crankshaft
THE PUMP IS NOW READY FOR ALL OTHER ASSEMBLIES. (SEE THE PUMP ASSEMBLY SHEETS). All bolting should be
reasonably snug to avoid leakage.
PARTS LIST
BRONCO - 2 AND BRONCO - 8
DUPLEX PISTON PUMPS
DIMENSIONS (INCHES)
WEIGHTS
AL C.I.B.
MODELS MODELS
24 Pounds 42 Pounds
11 kg 19 kg
REF. NO. PART NO. NO. REQ'D. DESCRIPTION
1 P45-1 1 Pump Body
1A P45-42 1 Bearing Sleeve
2 P45-26 2 Wear Pad
3 P1-2 1 Grease Fitting
4 B2-1 1 Bearing Cup
5 B2-1 1 Bearing Cup
6 B2-3 2 Bearing Cone with Seal
7 P45-47 1 Crankshaft, Bronco 2 or,
7 P45-48 1 Crankshaft, Bronco 8
8 P68-25 1 Eccentric Bearing Spacer
9 Bl-3 1 Eccentric Bearing
10 P5-4 1 Bearing Retainer Washer
11 H7-1 1 3/8" Lock Washer
12 P5-3 1 Grease Fitting
14 P21-2 1 Keyed Bearing Washer
15 B3-2 1 Lock Washer
16 B3-1 1 Lock Nut
17 P45-36 2 Ceramic Cylinder Liner
18 P45-16 2 Piston Spacer
19 P45-17 2 Phenolic Piston
20 P45-18 2 Backing Washer
21 P46-7 2 Piston Cup
22 P45-33 2 Piston Cap
23 D9-113 2 0 Ring
24 P45-34 2 Piston Bolt
25 P49-1 2 Hardened Yoke Pad
26 P49-2 1 Yoke
27 P49-3 1 Bearing Shield (Not Shown)
30 P45-37 1 Cover
31 H6-2 2 3/16" SAE Flat Washer
32 H14-1 2 10-24 X 3/8" Machine Screw
33 P43-37 1 Grease Cap
34 P45-40 2 Cylinder Head
35 D9-117 4 0 Ring
36 P43-11 4 Valve Seat
37 P2-10 4 Valve Disc
38 Z28-1 4 Valve Spring
39 P43-9 4 Valve Cage
40 D9-127 4 0 Ring
41 P45-41 4 Valve Cap
42 Hl-4 8 3/8" X 1-1/2" UNC Socket Head Capscrew
42A P45-46 4 Retainer Bar
43 D9-120 4 0 Ring
44 D9-030 2 0 Ring
45 Hl-3 8 ½” X 2 ½” UNC Socket Head Capscrew
46 H3-3 8 ½” UNC Hex Nut
SERVICING
PISTON ASSEMBLY:
¾ If available, use a small amount of Teflon Lubricant on the outer surface of New Piston Cups.
¾ Assemble Piston Parts as Shown in the Drawing.
¾ Push the Piston Assembly into the Cylinder Liner making sure that the head of the Piston Bolt is at the end of the Cylinder Liner
where the Ceramic Liner is Flush with the surrounding Steel Jacket.
¾ Coat the outside of the Cylinder Liner with a suitable AntiSeize Compound.
¾ Use a suitable Locking Compound on that end of the Piston Bolt that threads into the Yoke Assembly .
¾ Install Piston and Liner Assembly in Pump.
PISTON CUPS:
¾ Some minor seepage may occur when the Temperature of the Fluid pumped is reduced. This seepage will usually stop if the lower
Temperature is maintained for several Hours or, the Temperature of the Fluid is returned to the higher level.
¾ If severe leakage occurs, Stop the Pump and Replace worn Parts. Continued operation with excessive leakage will damage Bearings.
LUBRICATION:
¾ See Grease Instruction Decal on Pump Cover.
TORQUE
FT./LBS.
Hl-4 3/8” X 1-1/2” UNC Socket Head Cap Screw.
Coat threads with an Anti-Seize Compound other than 15
white Lead.
Hl-3 ½” X 2 ½” UNC Socket Head Cap Screw. 30
P45-34 Piston Bolt - Use a Thread Locking Compound. 25
P5-3 Grease Fitting. 15
BRAHMA PUMP No. P-43-40
REF. NO PART NO. NO. REQ’D DESCRIPTION
1 P5-3 3 Special Capscrew W/Grease Fitting
2 - 2 3/8” Lock Washer
3 P43-28 1 Bearing Retainer Plate
4 R0931VLL 2 Eccentric Bearing
5 P43-23 1 Crankshaft 1-1/8” Stroke - Brahma 24
P43-26 Crankshaft 7/8” Stroke - Brahma 12
5A - 1 Machinery Bushing 48m
6 P43-24 1 Inner Bearing Spacer
7 P43-29 1 Inner Bearing Seal
8 5395 1 Timken Cone
9 5335 2 Timken Cup
10 P43-33 2 Piston Yoke
11 P43-34 4 Hardened Yoke Pad
12 P43-1 1 Body
13 -023 8 O Ring
14 P43-11-SS 8 Valve Seat
15 P2-10 8 Valve Disc
16 Z28-1 8 Valve Spring
17 P43-9B 8 Valve Cage
18 -127 8 O Ring
19 P45-41 8 Valve Cap
20 - 16 3/8” X 1” UNC Socket Head Capscrew
21 P45-40 4 Cylinder Head
22 -140 4 O Ring
23 -120 8 O Ring
27 P43-35 4 Ceramic Cylinder Liner W/Steel Outer Case
28 P43-20 4 Piston Spacer
29 P43-21 4 Phenolic Piston Skirt
30 P43-22 4 Backing Washer
31 P47-6 4 Piston Cup
32 P43-31 4 Piston Cap
33 -115 4 O Ring
34 P43-30 4 Piston Bolt
35 - 16 ½” X 2” NC Socket Head Capscrews
36 TN08 1 Timken Locknut
37 TW108 1 Timken Lockwasher
38 P43-25 1 Outer Bearing Spacer
39 P43-27 1 Outer Bearing Seal
40 5356 1 Timken Cone
41 P43-1-1 1 Bearing Sleeve