Replacing Casing Oil Seal Assembly

PREPARATION
Learning Objectives

Upon completion of this lesson, the trainee will be able to:

1. Remove worn and deteriorated packing.

2. Install new packing in accordance with manufacturer's specifications and
procedures.

3. Inspect and test for freedom of movement of the camshaft.

Reference Materials
Material Removed In Process Control Tag (SUBGEN QA Form 4355/5)
Applicable technical manual
Figures/Tables
None
Training Aids/Materials
Cam pump demonstrator
Shop tools
Deep well socket, 2-3/8 inches, 3/4-inch drive
Breaker bar, 3/4-inch drive
Self-sealing plastic bags
Studs, 3/8 inch-16 x 2-1/2 inches, with washers and nuts (2)
Allen wrench, 3/8 inch
Socket, 3/8 inch
Packing rings (four sets of three each)
Torque wrench, 0 to 50 foot-pound range
Feeler gage
O-rings (4)
Stud remover and resetter set
Special tool: packing assembly puller plate
Squirt oil can
Lube oil, Symbol 2190 TEP
Plug gaskets (4)
Torque wrench, 0 to 800 foot-pound range
Grease, MIL-G-24508
Outside micrometer, 0 to 1 inch
Shim stock, laminated
Garlock Blue-Gard gasketing, 1/32 inch or equivalent
Molykote
Packing rings, 1/4 inch, Johns Manville 255 or equivalent (8)
INTRODUCTION
Seal packing must be replaced whenever it becomes worn or deteriorated to eliminate
excessive leakoff of lubricating oil. New packing must be installed in accordance with
manufacturer's procedures to be effective and prevent loss of, and/or possible
contamination of, lube oil.
DISCUSSION
Removing worn or deteriorated packing

1. Remove push rod, gland nuts, and two rings of packing from the end plug.
2. With a socket wrench, remove the end plug from the pump cylinder.
3. Tag and bag all parts as they are removed.
4. Remove the plug gasket.
5. Install two 3/8 inch-16 x 2-1/2 inch studs to the packing compressor. Install the
puller plate, two 3/8-inch flat washers, and two 3/8 inch-16 nuts. Tighten the nuts
alternately and pull the packing assembly out straight without binding or cocking
it.
6. Remove the o-ring.
7. Remove the bolts from the cover.
8. Remove the cover.
9. Remove the plunger using a 3/8-inch Allen wrench.
10. Remove the excluder.
11. Remove the four hex head bolts and four lockwashers.
12. Remove the plunger lip seal keeper.
13. Remove the three rings of seal packing.
14. Repeat steps1 through 13 for the three remaining cylinders.

Installing new packing

1. Install and seat a new packing ring into the casing.

NOTE
These two W-shaped rings should be installed in such a manner that the larger
diameter portion of each ring is facing toward the casing.

2. Install and seat second new ring into the first ring of packing.

NOTE
When installing new seal packing, the third ring should be facing in the opposite
direction from the first two rings with the thicker diameter portion facing away from
the casing.

3. Place the third ring up against the second ring.

4. Slide the plunger into the stuffing box.
5. Reinstall the excluder and lip seal keeper onto the plunger.
6. Work the plunger through the seal packing, thread it into the slipper, and tighten
with a 3/8-inch Allen wrench.
7. Attach a 3/8-inch Allen wrench to a 050 foot-pound torque wrench and torque the
plunger to 24 foot-pounds.
 8. Check the compression of the seal assembly and, if necessary, use shims to
achieve a seal compression of 0.015 inch to 0.017 inch.
9. Secure the lip seal keeper with lockwashers and hex bolts.
10. Reinstall the cover.
11. Reinstall the cover bolts.
12. Install a new o-ring.
13. Lubricate the inner side of the plunger packing with a thin coat of lubricating oil.
14. Manufacture a 1/32-inch gasket for installation between the stuffing box sleeve
and throat bushing to help the o-ring seal the stuffing box sleeve.
15. Apply Molykote to the gasket and seat the gasket onto the throat bushing.
16. Install the packing cartridge onto the plunger.
17. Back out the push rod until the rod is flush with the face of the plug.
18. Install a new plug gasket.
19. Lubricate plug threads with grease.
20. Reinstall the plug to the pump cylinder.
21. Tighten the plug and torque it to 565 foot-pounds.
22. Reinstall the glands over the push rod.
23. Thread the push rod into the end plug.
24. Install two rings of 1/4-inch packing with butts 90 degrees apart.
25. Thread the gland nut into the end plug and tighten until firm.
26. Repeat steps 1 through 25 for the remaining three cylinders.

Inspecting and testing

1. Rotate the camshaft by hand.

2. Observe for proper freedom of movement.

APPLICATION
No formal test will be given. Ensuring that applicable safety precautions are followed at
all times, the instructor will observe trainees and provide applicable feedback until they
satisfactorily demonstrate the ability to:

1. Remove worn and deteriorated packing.

2. Install new packing in accordance with manufacturer's specifications and
procedures.
3. Inspect and test for freedom of movement of the camshaft.