Serva Pump

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SERVICE MANUAL
TPB/TPC/TPD600
SERVA TPB/C/D 600 Service Manual
Part Number: A08012930E Rev: C
TABLE OF CONTENTS
SAFETY PRECAUTIONS………………………………………………………1
SECTION Ⅰ -BASIC DESCRIPTION:
Pump Description ....................................................................................... .3
Performance Data / Installation Drawing ................................................. .4
LH Gearbox Locations ............................................................................... .7
RH Gearbox Locations ............................................................................... .8
Tach Drive/Rate Meter Calibration Specification ...................................... .10
Shipping and Storage .................................................................................. 14
SECTION Ⅱ - INSTALLATION DETAILS:

Pump Installation Highlights .................................................................... 16
Power End lube System Requirements ..................................................... 17
Recommended Power End Lube Oils ......................................................... 20
Plunger Lube System Requirements ........................................................... 22
Recommended Plunger Lube Oil................................................................ 23
SECTION Ⅲ - PUMP OPERATION AND MAINTENANCE:

Startup and Break-in Procedure.......... ........................................................ 25
Trouble-Shooting Guide ............................................................................. 29
Routine Preventive Maintenance ................................................................ 31
Fluid End Repair Procedures ...................................................................... 33
Power End Repair Procedures .................................................................... 37
Torque Table ............................................................................................... 41
SECTION Ⅳ - PUMP PARTS INFORMATION:

Power End Part Lists.......... ........................................................................ 42
Fluid End Part Lists .................................................................................... 51
Accessories ................................................................................................. 62
SERVA TPB/C/D 600 Service Manual
Safety Precautions
Follow all of the following safety precautions when you operate a

TPD600 pump. Failure to follow all of the following precautions
can result in serious bodily injury, death, and equipment damage.
1. Before you work on a 600 pump, check the following items:

2. Wear personal protective equipment (PPE). Review the PPE manual for
specifications on hard hat, goggles, gloves, steel-toed shoes, etc.
3. Flush the pump to remove any add or other harmful chemicals that could cause
bodily harm if contacted.
4. Carefully bleed pressure from the fluid end. Isolate the pump from pressure and
vent the pump to the atmosphere before beginning work
5. Turn off the prime mover (engine or electric motor).
Never place your hands in the fluid end, the area

between the fluid end and the power and the input
flange, when the prime mover is on. Serious injury
could result.
6. Disengage the prime mover from the pump (transmission in neutral) or lock the
electric motor to prevent accidental startup.
7. File smooth (or replace) parts that have sharp or jagged edges.
8. Use a remote-operated choke to build pressure in a 600 pump
Never use a full-close valve to build pressure in a positive-

displacement pump. A sudden overpressure could occur, causing
serious damage and bodily harm.
9. Use care when lifting or moving pump parts. Many of these parts are heavy
enough to cause injury if improperly handled. Lift pump parts with other
personnel or use a hoist or other lifting device.
10. If the pump input shaft is turned by a tool (such as a pry bar or pipe wrench),
remove the tool immediately after use.
Do not start the pump when the tool is still attached to the
driveshaft. Serious damage or injury could occur.
11. Before starting the pump, make sure all discharge valves are open and all
--1--
SERVA TPD600 Service Manual
protective guards are installed.

12. Never weld on a pressure-containing part (such as a fluid end, discharge flange,
etc. without prior approval of the Operations Technology Systems.
When use the flammable oil to wash the pump parts, advert on fire.
--2--
Section I BASIC INFORMATION

TPB/C/D 600 PUMP DESCRIPTION
The SERVA TPB/C/D600 is a reciprocating, positive displacement, horizontal
single-acting, triplex plunger pump which is rated at 600 Brake Horsepower input
maximum. The pump is designed for duty well service applications such as acidizing,
cementing, fracturing, well killing, gravel packing, etc.
The TPB/C/D600 Pump consists of a Power End, Speed Reducer Assembly and a
Fluid End Assembly. TPC600 pump have a additional connecting BOX assembly. The
Speed Reducer can be installed on either the right hand or left hand side of the pump
and can be installed in any one of 16 different input shaft locations to accommodate a
number of different pumping unit drive train configurations. Two different fluid
cylinders are available to accommodate several plunger sizes for a variety of pressures
and volumes.
Optional packing assemblies, valve assemblies, discharge flanges, suction manifolds,

etc. are available for a wide variety of unitization arrangements; for the pumping of
various specific fluids; and for service in a wide range of ambient conditions. The
weight of the pump will vary slightly depending on plunger size and other options but
will not vary more than plus or minus 5% of the advertised weight.
TPB/C/D600 pump can be used to pump the liquid medium in the well service. But
the TPB/C/D600 pump is not rated for sour gas service, such as H2S. TPB/C/D600
pump works where ambient temperature ranges from -30℃ to 45℃. If the ambient
temperature exceeds the limits, please contact SERVA Engineer Department.
--3--
SERVA Model TPB/C/D600 PLUNGER PUMP

Performance Data 1*
Rated Max. Brake Horsepower 600 BHP (447Kw)
Max. Rod Load 100,000 LBF (43,360 kg)
Stroke Length 6” (152.4mm)
Gear Ratio 4.6:1
Length 50.25”(1276mm)
Width 52.93”(1344mm)
Height 23.88”(607mm)
Weight Dry(Approx.) 4,600 LBS (2086kg)
Performance Data 2*
Plunger DISPLACEMENT AT PUMP STROKES PER MINUTE/PINION RPM
Output
Diamete
Per REV 50/230 120/552 200/920 300/1380 450/2070
r
Gal/rev
In gpm PSI gpm PSI gpm PSI gpm PSI gpm PSI
(liter/re
(㎜) (lpm) (MPa) (lpm) (MPa) (lpm) MPa (lpm) (MPa) (lpm) (MPa)
v)
2 3/4” .46 23 16,836 56 16,665 93 9,999 139 6,666 208 4,444

(69.9) (1.8) (87) (116.1) (210) (116.9) (350) (69.0) (526) (46.0) (788) (30.7)
3” .55 28 14,147 66 14,003 110 8,402 165 5,601 248 3,734

(76.2) (2.1) (104) (97.6) (250) (96.6) (417) (57.9) (625) (38.6) (938) (25.8)
3 1/2” .75 37 10,394 90 10,288 150 6,173 225 4,115 337 2,744
(88.9) (2.8) (142) (71.7) (341) (71.0) (568) (42.6) (851) (28.4) (1277) (18.9)
4” .98 49 7,958 118 7,877 196 4,726 294 3,151 441 2,100
(101.6) (3.7) (185) (54.9) (445) (54.3) (741) (32.6) (1112) (21.7) (1668) (14.5)
4 1/2” 1.24 62 6,288 149 6,224 248 3,734 372 2,489 558 1,660
(114.3) (4.7) (235) (43.4) (563) (42.9) (938) (25.8) (1407) (17.2) (2111) (11.4)
INPUT POWER:
253(188) 600(448) 600(448) 600(448) 600(448)
BHP(Kw)
*Based on 90% ME and 100 %VE- Intermittent Service Only.
M.E: Mechanical efficiency; V.E.: Volumetric Efficiency of Pump
--4--
Installation Detail Drawing (TPB/D600)
--5--
Installation Detail Drawing (TPB/D600)
--6--
--7--
--8--
PUMP NAMEPLATE
The nameplate contains information of pump type, Max.
pressure, plunger size, and Serial No.
--9--
Atex Marking:

Directive:
Corresponds
To 94/9/EC
Equipment group
Ⅱ : All applications
except mining
Category 2
High level of
protection
Atmosphere G : Gases D: Dusts
Use in Zone 1 Zone 21
Type of protection:
C : Constructional
Safety
Temperature Class:
T3 : Permissible surface
temperature 200℃
The Applicable standards and Technical specification:
EN13463-1 ; EN13463-5 & EN1127
- - 10 - -
TACH DRIVE/RATE METER CALIPRATION SPECICATIONS
SERVA TPB/C/D600
PLUNGER *FLUID DISPLACEMENT
DIAMETER PER TACH DRIVE REVOLUTION PER TACH DRIVE REVOLUTION
INCHES @ 95% V.E. @ 100% V.E.
(㎜) GPR BPR LPR GPR BPR LPR
2 3/4”
.0879 .00209 .3328 .0926 .00220 .3504
(69.9)
3”
.1047 .00249 .3961 .1102 .00262 .4170
(76.2)
3 1/2”
.1424 .00339 .5391 .1499 .00357 .5675
(88.9)
4”
.1860 .00443 .7042 .1958 .00466 .7413
(101.6)
4 1/2”
.2355 .00561 .8912 .2479 .00590 .9382
(114.3)
NOTE: THE VOLUMETRIC EFFICIENCY AND RESULTING DISPLACEMENT WILL VARY

SLIGHTLY DUE TO OPERATIONAL FACTORS SUCH AS PUMP SPEED,
SUPERCHARGE CONDITIONS, AND THE SPECIFIC GRAVITY OF THE FLUID
BEING PUMPED.
V.E. = VOLUMETRIC EFFICIENCY OF PUMP

GPR = U.S. GALLONS PER REVOLUTION
BPR = U.S. BARRELS PER REVOLUTION
LPR = LITER PER REVOLUTION
- - 11 - -
USEFUL PUMP DATA FORMULAS
A ----------------- Area (sq. in.)

BHP ------------- Brake horsepower
BPM ------------- Barrels per minute (U.S.)
FV --------------- Flow velocity (ft./sec.) A
GPM ------------- Gallons per minute (U.S.)
GPR ------------- Gallons per revolution (U.S.)
HHP ------------- Hydraulic horsepower 4M
ID ---------------- Inside diameter (inches)
ME --------------- Mechanical efficiency
NC --------------- Number of cylinders (per pump)
PD --------------- Plunger diameter (inches)
PSI --------------- Lbs./sq. in.
R.L--------------- Rod load (lbs.)
RPM ------------- Crankshaft revolutions per minute
SL ---------------- Stroke length (inches)
T ----------------- Torque (ft. lbs.)
- - 12 - -
Parts General Information

SERVA stocks a large inventory of genuine “original equipment” replacement parts
for each of its pumps. In order to expedite a parts order and avoid any delays, please
provide the Mowing information with your order:
1. The part number and description (refer to drawings and parts lists in this
section) of each item ordered.
2. The quantity of each part, kit, or assembly ordered.
3. The model number and serial number of the pump (see identification tags on
the fluid end and power end).
4. Your purchase order number.
5. Specify method of shipment complete shipping address, complete billing
address and telephone number at the destination of the shipment.
Pump Noise
When the pump is working, there is the pump noise more or less. Normally, the
working horsepower is more and the stroke times is more, the noise is more. The table
below list the TPD600 4 1/2” pump noise on full rated work horsepower which used
the Alison HT750 transmission.
Only for reference:
Transmission Noise at Noise at Background Noise dB(A)

Pinion
Gear power end fluid end At power
Speed At fluid end
Location dB(A) dB(A) end
1st 230 92.9 94.1 83.2 87.2
2nd 552 97.8 95.4 83.0 86.5
3rd 920 93.4 91.1 85.0 89.0
4th 1380 97.2 95.3 84.5 92.2
5th 2070 109.3 105.4 92.3 101.2
- - 13 - -
SHIPPING AND STORAGE

All pumps are shipped dry and must be flushed and filled with the proper lubricant
before operating (see Section2). Pumps may be flushed with diesel or light oil. When
pumps are shipped by ocean cargo, care should be taken to crate the pump in a
watertight container and ship below deck to prevent salt water contamination.
New pumps are not prepared for long periods of storage and should be put in service
as soon as possible. To prepare a pump for storage after prior use, clean the fluid end
and flush it with a good rust preventive, Plug all fluid end discharge and suction
openings. Drain oil from power end, thoroughly clean and flush with a good rust
preventive that will not clog oil passages. Remove crankcase breather and plug all
openings. Coat the pinion extensions and pony rods with a heavy rust preventive.
Store pump inside, in a warm, dry place.
Pumps that have sat idle for any appreciable period of time (two weeks or more) must
have the plungers and valves removed, coated with a light lubricant and reinstalled
prior to operating. The elastomeric plunger packing and valve inserts will stick to the
matching metal parts and become damaged upon startup if not disassembled and
lubricated first.
When the pump is transited, we recommend the forklift and the crane. The picture
followed shows the method we normally used.
A. Forklift
- - 14 - -
B.Crane
- - 15 - -
Section Ⅱ INSTALLATION DETAILS

PUMP INSTALLATION HIGHLIGHTS
The proper installation of your SERVA well service pump is a must in obtaining long
life and trouble free service. Particular attention must be given to the following items:
A. Power Source:
The prime mover (usually a 2100 RPM diesel engine) should not be rated at
more than 725 BHP intermittent service in order to avoid overpowering the
pump.
B. Drive train:
The drive train which connects the pump to the engine should include a
transmission (5 speed or more) and a mechanical driveline with universal joints
and a slip joint in order to fully utilize the pump's wide range of pressure and
flow capabilities.
A powershift type transmission with integral torque converter and automatic
lock-up clutch will provide the most trouble-free means of shifting under
pressure. When using an ordinary mechanical transmission with manual clutch,
extreme caution must be exercised when clutching and shifting in order to avoid
introducing severe shock loads to the pump's input shaft. When using any
transmission with a “high gear or "overdrive" ratio greater than 1.0: 1, the
"overdrive" gear range must be blocked out in order to avoid over speeding the
pump. When using a transmission with a torque converter and/or a low gear ratio
of 5.0:1 or lower, extreme caution should be exercised to avoid over-pressuring
the pump when operating in low gear or converter mode.
The mechanical driveline should have a "Diesel Engine Use" torque rating of
approximate 1250 to 1700 ft. lbs. (6500 to 8900 ft. lbs. Short Duration) and
should have no less than 1” slip capacity. The manufacturer's recommendations
for maximum installed angle, maximum RPM, etc. must not be exceeded.
- - 16 - -
POWER END LUBE SYSTEM REQUIREMENTS

Providing a well designed trouble-free power end lube system is one of the most
important factors in obtaining maximum service and long life from the TPB/C/D 600
Well Service Plunger Pump. Due to the nature of well servicing operations, the
highest pump pressures and highest load conditions occur at very slow pump speeds.
This characteristic of well service pump operation necessitates the use of an engine
driven lube pump which will deliver maximum lube oil volume at high engine speeds
regardless of slow pump speeds. As a result of this operating characteristic and the
many different equipment design possibilities, it is not feasible for SERVA to provide
a power end lube system with the pump. The equipment manufacturer who builds the
powered well service unit must provide power end lube system components which are
compatible with the specific engine, transmission, etc. being utilized on the unit.
A properly designed power end lube system will meet the following specifications:
1. Oil Reservoir:
A. Must be of 50 gallon capacity minimum.
B. Suction outlet to be 1½" minimum and located as deep as possible.
C. Return fitting for drainback to be 3" minimum; return fitting for relief valve
line to be F' minimum.
D. Dipstick or sight glass to indicate oil level in the reservoir.
E. A serviceable magnet located near the 3” return port is highly recommended
F. Breather filler cap to be 40 micron 25CFM minimum and should include a
built-in strainer to prevent trash from entering the reservoir.
G. Reservoir must be located below the lowest drain port in the plunger pump
and as near the plunger pump as possible (preferably directly underneath).
2. Lube Pump:
A. Must be a gear type pump rated at 12 GPM minimum at its installed
maximum RPM.
B. Inlet and outlet ports should be as large as possible w/ 1½” inlet and 3/4”
outlet preferred.
NOTE: If the gear pump suction inlet port is smaller than 1 1/2”, a swage
connection should be used on the suction port in order to maintain a 1 1/2”
suction line size as near the gear pump as possible.
C. A liquid filled vacuum gauge (0 to 30” Hg) should be installed as near the
gear pump suction port as possible in order to monitor the suction flow
conditions, especially during cold startups in cold weather.
D. The gear pump may be direct coupled to an accessory drive location on the
engine or can be direct, coupled to the transmission with a pump-mount
type power take-off (PTO). The transmission PTO mount usually offers the
advantage of a lower mounting and improved suction conditions. The lube
pump mounting must be a direct coupled positive drive arrangement which
- - 17 - -
operates at engine speed whenever the plunger pump’s prime mover is

running.
3. Lube System Pressure Lines and Oil Filter:

A. Pressure lines must be 3/4” I.D. minimum in order to maintain a flow a
velocity of 10 to 12 ft. per second maximum.
B. Pressure lines should be wire reinforced with a minimum working pressure
of 800 PSI.
C. The oil filter must be rated at 50 GPW200 PSI minimum, must have a
built-in 15 to 25 PSI relief valve, and 25 to 33 micron elements.
D. A liquid filled 0 to 200 PSI oil pressure gauge must be located at the ½”
NPT lube inlet on the plunger pump. An auxiliary oil pressure gauge is also
highly recommended for those units having remote control consoles.
E. When connecting the oil inlet, you must connect the three inlet to the lube
oil pipe.(See the following drawing)
4. Lube System Relief Valve and Relief Return Line:

A. The system relief valve should be a 3/4” 20 to 25 GPM. 60 PSI minimum
100 maximum, adjustable non-chattering type relief valve.
B. The relief valve must be located at the plunger pump’s 1/2” NPT lube port
opposite the lube inlet to insure oil flow throughout the plunger pump
before reaching the relief valve.
C. The relief return line should be 3/4” ID minimum, wire reinforced, rated at
800 PSI minimum operating pressure: and should return directly to the
reservoir.
5. Lube Drain Lines (from plunger pump to reservoir):
A. The TPB/C/D600 pump is equipped with a 2” NPT drain port in the speed
reducer (gearbox) housing and a 3” NPT drain port in the bottom of the
power end housing. The drain lines should never be smaller than the drain
- - 18 - -
port in the power end speed reducer and should be as short as possible. The
drain lines should be free of excessive bends and kinks and should flow
continuously downhill to the reservoir. If necessary, the 2” drain line from
the speed reducer can be teed into a common 3” drain line returning to the
reservoir. The lowest 2” NPT drain port in the speed reducer should always
be utilized for the drain line in order to prevent the speed reducer from
accumulating excess oil.
B. A 0 to 250F oil temperature gauge should be installed in the primary drain
line such that its sensor will be submerged in the return oil from the
plunger pump. The temperature gauge should also be located in a place
easily accessible for viewing. An auxiliary oil temperature gauge is also
highly recommended for those units which have a remote control console.
- - 19 - -
RECOMMENDED POWER END LUBE OILS

Selecting the proper grade of gear oil for adequate power end lubrication in various
climates is very important to obtaining long life and trouble-free service from your
SERVA well service plunger pump. In all cases, the gear oil selected should contain an
“extreme pressure” (EP) additive, should meet or exceed U.S. Mil. Spec.
Mil-L-2105B, and should have a Timken Test rating no lower than 45 lbs. Both
automotive and industrial type gear oils are shown in the following lists of acceptable
lube oils for various climates and ambient conditions.
1. General Service Lube Oils:
These oils are generally classified as an SAE 90 automotive grade and are
recommended where ambient temperatures range from 20 to 90 degrees Fahrenheit.
These oils have a pour point of approximately 0F and a viscosity rating of 85 SUS or
more at 210 degrees Fahrenheit. The plunger pump’s oil temperature must not exceed
175 degrees Fahrenheit when using one of these oils.
Amoco ........................................................................ Amogear MP90

Arco ............................................................................ Arco Gear Oil #90
Chevron (standard oil) ................................................ NL Gear Compound #220
Cities Service .............................................................. Citgo EP Compound 90
Conoco........................................................................ Conoco DN 600 Gear Oil
Exxon.......................................................................... Gear Oil GX90
Spartan EP220
Gulf ........................................................................... Transgear EP90
EP5120
Mobil .......................................................................... Mobilube HD90
Mobilube SHC 75W90
Pennzoil ...................................................................... Maxol EP Gear Oil #3
Phillips 66 ................................................................... All Purpose Gear Oil SAE90
Phil Lube SMP 80W90
Shell ............................................................................ Spirax HD90
Omala 71
Sun Oil Company ....................................................... Sunfleet GL-5 90 Wt.
Sunep 1070
Texaco......................................................................... Multigear EP90
Meropa 220
- - 20 - -
RECOMMENDED POWER END LUBE OILS

2. Extreme Cold Weather Lube Oils:
These oils are generally classified as an SAE 80 automotive grade or an AGMA #3EP
industrial grade and are recommended where ambient temperatures range from -25F
to 70F. These oils have a pour point of approximately -25F and a viscosity rating of
55SUS at 210F. The plunger pump's oil temperature must not exceed 130F when
using one of these oils.
Chevron (standard oil) ....................................................... Universal Gear Lubricant
80W90
Conoco ................................................................................. Conoco DN 600 Gear Oil
Exxon ................................................................................... Gear Oil GX80
Mobil .................................................................................... Mobilube SHC 626
Philips 66 ............................................................................. Phil Lube SMP 80W-90
Shell ..................................................................................... Spirax HD80
Texaco .................................................................................. Multigear EP SOW
Meropa 150
3. Extreme Hot Weather Lube Oils:
These oils are generally classified as an SAE 140 automotive grade or an AGMA #7
EP industrial grade and are recommended where ambient temperatures range from
35F to 110F. These oils have a pour point of approximately 20F and a viscosity rating
of 140 SUS at 210F. The plunger pump's oil temperature must not exceed 195F when
using one of these oils.
Amoco ................................................................................ Amogear MP 140

Chevron .............................................................................. Universal Gear Lubricant
85W-140
Conoco ............................................................................... .Universal Gear Lube S
AE 140
Exxon ................................................................................. Spartan EP #6
Gulf .................................................................................... EP 5150
Mobil .................................................................................. .Mobilube HD 140
Mobilube SHC 634
Phillips 66 .......................................................................... Phil Lube SMP 85W- 140
Shell ................................................................................... .Omala 77
Texaco ................................................................................ Multigear EP 140
- - 21 - -
PLUNGER LUBE SYSTEM REQUIREMENTS

SERVA TPB/C/D 600 pumps are designed for packing lubrication with oil rather than
grease. Exceptionally long packing life can be expected providing proper lubrication
is supplied to the plunger packing lube port above each stuffing box. Ample plunger
and packing lubrication can be achieved with an inexpensive relatively trouble-free
low-pressure air operated “lubricant pump” type system. Mechanically driven plunger
lubricators are not recommended due to the well service pump’s extreme variations in
pump speeds. A properly designed packing lube system will meet the following
specifications:
1. Oil Reservoir:
A. Should be of approximately 5-gallon capacity.
B. Should be equipped with a sight glass or dipstick.
C. Should be equipped with a breather/filler cap that has a built-in strainer to
prevent trash from entering the reservoir.
2. In-Line Relief Valve:

It is critical that an in-line relief valve be included in the circuit when plunger wiper
rings are used with the packing. Otherwise, excessive lube pressure will damage the
wiper.
A. Should have a cracking pressure of 32 PSI.
B. Should be equipped with a pressure gauge between the relief valve and lubricant
Pump.
C. A return line should be connected from the relief valve to the oil reservoir so
that vented oil will return to the oil reservoir.
3. Flow Control Needle Valves:

A. Should be a 1/4" needle valve, which can be locked at any given setting after
adjustment.
B. Must be installed in each lubricant flow line which leads to the individual
packing lube ports in the plunger pump fluid cylinder.
4. High Pressure Check Valves:

A. Must be rated at or above the well service plunger pump's maximum pressure
rating.
B. Must be installed in the packing lube port so that the direction of flow is into the
fluid cylinder.
- - 22 - -
RECOMMENDED PLUNGER LUBE OILS

Selecting the proper grade of plunger lube oil for adequate plunger lubrication in
various climates is very important to obtaining long life and trouble-free service from
your SERVA well service plunger pump. In all cases the “rock drill” oil selected
should contain an "extreme pressure" (EP) additive, should have a film strength of
300,000 PSI or more and should have a relatively low coefficient of static friction.
Acceptable plunger lube oils for various climates are shown below:
1. General Service (above 32 degrees Fahrenheit)

Amoco ............................................................ Amoco Rock Drill Oil-Heavy
Arco ................................................................ Arco Truslide S-700
Chevron .......................................................... Vistac # 14-X
Conoco ........................................................... EP Rock Drill #78
Exxon ............................................................. Aprox #85
Gulf ................................................................ Rock Drill #92
Mobil .............................................................. Rock Drill Oil RL 668E
Phillips 66 ...................................................... Rock Drill EP 500
Shell ............................................................... Torcula Oil #75
Skelly ............................................................. Shell-Roe #65
Sun Oil ........................................................... Rock Drill 1000
Texaco ............................................................ Rock Drill Oil EPH
2. Extreme Cold Weather Service (below 32 degrees Fahrenheit):

Amoco ............................................................ Amoco Rock Drill Oil-Light
Arco ................................................................ Arco Truslide S-315
Chevron .......................................................... Vistac #7-X
Conoco ........................................................... EP Rock Drill # 17
Exxon ............................................................. Aprox #45
Gulf ................................................................ Rock Drill #44
Mobil .............................................................. Rock Drill Oil RL 668B
Phillips 66 ...................................................... Rock Drill EP 300
Shell ............................................................... Torcula. Oil #25
Sun Oil ........................................................... DX Rock Drill Oil L509
Texaco ............................................................ Rock Drill Oil EPL
- - 23 - -
RECOMMENDED PLUNGER LUBE OILS
For all styles of packing, the plunger lube is absolutely critical for good packing and
plunger life. Failure to provide adequate or appropriate lube will cause the packing to
fail and cause damage to mating components.
SERVA recommends the use of Rock Bit or Way Oil that meets the following
specifications:
ISO Grade 32 68
CPS No. 232500 232511
AGMA Grade ---- 2
API Gravity 21.4 25.6
Viscosity, Kinematics
cSt at 40℃ 30.4 64.6
cSt at 100℃ 4.9 7.3
Viscosity, Saybolt
SUS at 100℉ 158 338
SUS at 210℉ 42.7 50.8
Viscosity Index 74 61
Flast Point, C (F) 170(338) 200(389)
Pour Point, C (F) -45(-49) -24(-11)
Lubricants that fail to meet these specifications, and especially "used crankcase oils",
are unacceptable.
Startup is a critical time for plunger packing. Lubrication should flow freely to
plunger prior to stroking the pump. Although conditions will vary, generally twenty
(20) drops per minute lube oil rate is recommended. Stroking dry plungers can
cause the header ring and packing to tear and fail.
- - 24 - -
Section Ⅲ
PUMP OPERATION AND MAINTENANCE
TPB/C/D 600 STARTUP AND BREAK-IN PROCEDURE
Each new pump must undergo a brief but thorough startup and break-in procedure in
order to verify the field worthiness of the unitized pumping system and in order to
allow a gradual “wearing in” of various mating parts in the pump itself. The following
guidelines have been established by SERVA to minimize startup problems and insure
maximum service from the plunger pump:
A. Inspection Prior to Starting Engine:

1. Check to see that all masking tape, rust preventative, etc. has been removed
from moving parts such as plungers, pinion shaft, etc.
2. Check to see that the plunger pump is securely bolted to skid or truck frame.
3. Check to see that the driveline is securely fastened to the plunger pump's input
shaft and that adequate slip is present in the driveline's slip joint.
4. Check to see that the power end lube oil reservoir was flushed and drained then
filled with the proper type of gear oil.
5. Check to see that the plunger lube oil reservoir was flushed and drained then
filled with the proper type of rock drill oil.
6. Check to see that the supercharge piping system has been completely flushed
and all piping connections are tight.
7. Cheek to see that the power end lube system startup adjustments and plunger
lube system startup adjustments were performed.
8. Check to see that the suction pulsation dampener has been precharged properly.
9. Check to see that the primary suction piping is connected to an adequate supply
of cool clean water for testing.
10. Check to see that the plunger pump's discharge piping is safely installed all the
way back to the water reservoir. Check to see that all connections are tight and all
valves are open.
11. Start the supercharge pump and flush all air from the entire system.
12. Follow the engine manufacturer's recommendations for engine startup and
warmup.
- - 25 - -
TPB/C/D600 STARTUP AND BREAK-IN PROCEDURE
B. Warmup Procedure Prior to Rotating the Plunger Pump:

1. While operating the engine at idle and transmission in neutral, check the power
end lube pump vacuum reading, the power end lube oil pressure, and the power end
lube oil temperature. If the lube pump vacuum reading is less than 10” Hg,
gradually increase the engine RPM to determine whether full engine RPM can be
reached without exceeding 10” Hg at the power end lube pump- suction inlet.
2. Continue running the engine at or below 10” Hg lube pump vacuum as
necessary to warm and thin the power end lube oil. The plunger pump should not be
rotated until full engine RPM can be achieved without exceeding 1V Hg at the lube
pump suction inlet or until the power end lube oil temperature reaches 60F
minimum.
C. Plunger Pump Valve Seating Procedure:

1. In order to protect the fluid cylinder from washing before sustained pumping
begins, the tapered valve seats must be pressured up and fully seated creating a
positive fluid seal.
2. Adjust the test choke for high pressure/low pump RPM. Shift the transmission to
1st gear and slowly increase the throttle setting to achieve 85% of the pump’s
maximum rated rod load for 2 to 3 minutes or until a series of audible popping
noises are heard. This indicates the seats have properly set in the taper. The
desired pressure for each plunger size is as follows:
Plunger Dia. 85% Rated Pressure
2 3/4” 14,320PSI
3” 12,030PSI
3 1/2” 8,840PSI
4” 6,765PSI
4 1/2” 5,345PSI
During this portion of the startup procedure, closely observe the plunger pump for any
unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end
lube oil pressure, supercharge pressure, etc. After returning the engine to idle and
transmission to neutral, physically inspect the plunger pump before proceeding
further.
- - 26 - -

D. Break-In Procedure:
1. Adjust the test choke, engine, and transmission to obtain approximately 35% rated
rod load, 35% rated pump RPM, and 42% rated horsepower. These settings should
be approximately as follows:
Plunger Dia. Pump RPM GPM/BPM PSI BHP
2 3/4” 143 66/1.57 5,895 250
3” 143 79/1.88 4,955 250
3 1/2” 143 107/2.55 3,640 250
4” 143 140/3.33 2,785 250
4 1/2” 143 177/4.21 2,200 250
Run the plunger pump at this setting for one hour. During this time, closely observe
the plunger pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record
all pertinent information such as elapsed time, ambient temperature, power end lube
oil temperature, power end oil pressure, supercharge pressure, etc. After returning the
engine to idle and the transmission to neutral, physically inspect the plunger pump
before proceeding further.
road load, 50% rated pump RPM, and 75% rated horsepower. These settings
should be approximately as follows:
2 3/4” 225 104/2.48 6,740 455
3” 225 124/2.95 5,660 455
3 1/2” 225 169/4.02 4,160 455
4” 225 221/5.26 3,185 455
4 1/2” 225 279/6.64 2,515 455
Run the plunger pump at this setting for one hour. During this time, closely observe
the plunger pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record
all pertinent information such as elapsed time, ambient temperature, power end lube
oil temperature, power end lube oil pressure, supercharge pressure, etc. After
returning the engine to idle and the transmission to neutral, physically inspect the
plunger pump before proceeding further.
rod load, 100% rated pump RPM, and 83% rated horsepower. These settings should
be approximately as follows:
- - 27 - -
Plunger Dia. Pump RPM GPMIBPM PSI BHP

2 3/4” 450 207/4.93 3,705 500
3” 450 248/5.90 3,115 500
3 1/2” 450 338/8.05 2,290 500
4” 450 441/10.50 1,750 500
4 1/2” 450 558/13.29 1,385 500
Run the pump at this setting for 30 minutes. During this time, closely observe the
plunger pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all
pertinent information such as elapsed time, ambient temperature, power end lube oil
temperature, power end lube oil pressure, supercharge pressure, etc. After returning
the engine to idle and the transmission to neutral, physically inspect the plunger pump
before proceeding further.
4. Adjust the test choke, engine, and transmission to obtain approximately 100%
rated rod load, 12.5% rated pump RPM, and 47% rated horsepower. These settings
should be approximately as follows:
2 3/4” 57 26/0.62 15,000* 285
3” 57 31/0.74 14,155 285
3 1/2” 57 43/1.02 10,400 285
4” 57 56/1.33 7,960 285
4 1/2” 57 71/1.69 6,290 285
Run the pump at this setting for 30 minutes. During this time, closely observe the
plunger pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all
pertinent information such as elapsed time, ambient temperature, power end lube oil
temperature, power end lube oil pressure, supercharge pressure, etc. Return the engine
to idle, the transmission to neutral, and kill the engine.
5. Visually inspect the power end for oil leaks around the plunger seals, pinion seal,
lubrication hoses, lube drain hoses, covers, etc. Visually inspect the fluid end for fluid
leaks around the suction covers, discharge covers, discharge flanges, stuffing boxes,
and suction manifold. Visually inspect the plungers for any signs of heating or scoring.
Remove the power end lube system magnet and inspect for any unusually large
particles of metal. Change the lube oil -filters.
* Pressure is limited to 15,000 PSI due to discharge flange and plunger configuration.
For higher pressure, contact SERVA engineering department.
- - 28 - -
TROUBLESHOOTING GUIDE
TROUBLE SYMPTOM: PROBABLE CAUSE:

A) Abnormally high vacuum 1. Extremely cold ambient temperature/dangerously
at power end lube pump high oil viscosity.
suction inlet (may or may not 2. Clogged lube system suction strainer.
be accompanied by 3. Kinked or collapsed lube system suction hose.
abnormally low oil pressure). 4. Clogged oil reservoir breather.
5. Erroneous gauge reading.
B.) Abnormally low power 1. Leak in lube pump suction piping, which allows
end lube oil pressure with air to be drawn into the system.
normal to low vacuum reading 2. Worn or damaged lube pump.
at lube pump suction (may or 3. Leak in lube pump pressure piping.
may not be accompanied by 4. Low oil level in reservoir.
high oil temperature). 5. Clogged oil filter element.
6. Faulty lube system relief valve.
7. Extremely hot lube oil temperature/dangerously
low oil viscosity.
C) Abnormally high power 1. Extremely warm ambient temperature/dangerously
end lube oil temperature (may low oil viscosity/incorrect grade of gear oil.
or may not be accompanied 2. Gear oil contaminated with water, trash, or air
by low oil pressure). bubbles.
3. Plunger pump has been operated continuously for
too long a period of time at or near its maximum
horsepower or torque rating.
4. Heat exchanger or oil cooler malfunction.
6. Internal power end damage or power end wear.
D) Leaking power end oil 1. Extremely cold ambient temperature/high oil
seals. viscosity.
2. Damaged seal surface on mating part.
3. Clogged oil breather/high crankcase pressure.
4. Worn or damaged seal.
5. Contaminated lube oil.
- - 29 - -
TROUBLESHOOTING GUIDE
TROUBLE SYMPTOM: PROBABLE CAUSE:

E.) Leaking fluid end seals. 1. Seal installed improperly.
2. Seal cut or pinched on installation.
3. Mating seal surface not cleaned properly prior to
seal installation.
4. Damaged or corroded mating seal surface.
5. Sealing part not properly tightened.
F) Plunger and/or packing 1. Packing nut not tightened properly.
fluid leak. 2. Worn or damaged packing.
3. Packing installed improperly.
4. Mating seal surface not cleaned properly prior to
packing installation.
5. Damaged or corroded mating seal surface.
6. Fluid being pumped is incompatible with the style
packing being used.
G) Fluid knock or hammer. 1. Air entering supercharge system through loose, worn
or damaged connections.
2. Air entering supercharge system through leaking
charge pump seals.
3. Fluid being pumped contains gas or vapor .
4. Insufficient supercharge flow or pressure.
5. Valve cocked open/broken valve spring or valve
stop.
6. Worn or damaged valve, valve insert, or valve seat.
7. Improperly charged or ineffective suction pulsation
dampener.
H) Low discharge 1. Worn or damaged valve, assembly.
pressure/rough running 2. Insufficient supercharge flow or pressure.
pump. 3. Air, gas, or vapor in fluid being pumped.
4. Improperly charged or ineffective suction pulsation
dampener.
5. Two or more plunger pumps being supercharged by
a common charge pump and being allowed to get “in
phase” with each other.
- - 30 - -
ROUTINE PREVENTIVE MAINTENANCE

Maximum service and trouble-free operation can be obtained from the SERVA well
service plunger pump by establishing a thorough preventive maintenance program as
follows:
A. During The First 100 Hours Of New Pump Operation:
1. Change power end lube oil filters every 25 hours (or more often if required) to
prevent filter bypass.
2. Thoroughly clean the power end lube oil suction strainer after the first 50 hours
and 100 hours operation.
3. Change the power end lube oil after the first 100 hours operation and clean the
lube oil reservoir.
B. Daily Preventive Maintenance:
1. Check the oil level in the power end lube oil reservoir.
2. Check the oil level in the plunger lube oil reservoir.
3. Check the plunger pump for oil leaks and/or fluid leaks.
4. Check the power end lube oil system for leaks.
5. Check the plunger lube system for leaks.
6. Check the supercharge piping for leaks.
C. Weekly Preventive Maintenance:
1. Check all items on “daily” list.
2. Check all valves, inserts, valve seats, and springs.
3. Check all discharge and suction cover seals.
4. Check suction pulsation dampener for correct pre-charge.
D. Monthly (or every 100 hours) Preventive Maintenance:
1. Check all items on “daily” and “weekly” lists.
2. Check all fluid cylinder mounting bolts to insure that they are tight.
3. Check all plunger pump mounting bolts to insure that they are tight.
4. Change power end lube oil filters.
5. Check all supplies needed for routine maintenance such as o-rings, fluid seals,
valves, valve inserts, valve seats, valve springs, packing, oil seals, filter
elements, etc.
E. Quarterly (or every 250 hours) Preventive Maintenance:
1. Check all items on "daily", "weekly", and "monthly" list.
2. Change the power end lube oil and refill with the proper grade of gear oil for
upcoming ambient conditions.
3. Thoroughly clean the power end lube oil suction strainer.
4. Remove and inspect the plungers and packing assembly components. Replace
all packing pressure rings and header rings.
5. Clean the plunger pump's oil breather and the power end lube oil reservoir
breather.
- - 31 - -
ROUTINE PREVENTIVE MAINTENANCE

F. Yearly (or as required) Preventive Maintenance:
1. Replace worn plungers and packing brass.
2. Replace worn or corroded valve covers, suction valve stops, packing nuts,
discharge flanges, pump tools, etc.
3 Replace all discharge flange seals and suction manifold seals.
4. Replace any defective gauges and instruments.
5. Inspect (and rebuild if necessary) the power end lube oil pump.
It is difficult to assess wear and tear on a pump based solely on hours operated, due to
the variations in duty cycle and types of service. However, roller bearings, rod
bearings and gearing may need replacing after approximately 3000 hours. With these
components, signs of extensive wear will generally show up as spalling (or flaking
off), of material causing pitting or scoring on the working surfaces. A small amount of
this is tolerable on gear faces, but any spalling on a bearing surface is an indication to
replace that item as quickly as feasible.
While replacement of these major components is relatively expensive, failure of a

main bearing can quite often lead to serious crankshaft and/or power frame damage.
Close observation of the lube oil filters during routine maintenance will generally
indicate the condition of roller bearings, gears, and journal bearings. A routine of
pulling the inspection covers and observing the condition of the bearings and gears
every 500 hours is recommended.
- - 32 - -
FLUID END REPAIR PROCEDURES

A. To remove Valves and Seats:
1. Using the SERVA 2" hex cover wrench and a 10 lb. hammer, remove the suction
covers and discharge covers from the fluid cylinder.
2. Turn the suction valve stops approximately 90 degrees and remove them from
the fluid cylinder along with the valve springs underneath them.
3. Using an SERVA magnetic valve removal tool, cock each suction valve to one
side in order to drain any fluid standing over it, and remove the valve from the
fluid cylinder. Follow the valve manufacturer's recommendation of removing the
insert from, the valve.
4. Remove the discharge valve springs and discharge valves from the fluid
cylinder.
5. Using an SERVA hydraulic scat puller assembly, remove each of the discharge
valve seats and suction valve seats.
6. The tapered valve scat bore in the fluid cylinder must be thoroughly cleaned and
lightly hand polished with a 220 to 240 grit emory cloth prior to installing new
valve seats.
7. Always install a new o-ring seal when reinstalling a valve seat. Do not use any
type of grease, sealer, etc.-the valve scat must be installed dry. Upon installing
the valve seat hand tight, install the valve in the seat and using a heavy steel bar,
hammer the valve seat into the taper.
8. When reinstalling the valves, do not mix one manufacturer's valve with another
manufacturer's valve seat. Likewise, do not mix one manufacturer's valve insert
with another's valve.
9. When reinstalling the suction valve stop, make certain it is turned perpendicular
to the plunger and securely seated in the groove in the cylinder.
10. Before reinstalling the discharge and suction covers, remove the seals from each,
clean the covers thoroughly, and install new seals in the same direction that the
old ones came off. Each cover bore in the fluid cylinder must be cleaned
thoroughly and lightly hand polished with a 220 to 240 grit emory cloth prior to
cover installation.
11. Upon installing the threaded suction and discharge covers with a coating of oil
or very light grease, tighten them securely with the 2" hex cover wrench and a
10 lb. hammer.
- - 33 - -

B. To Change Plungers and Packing:
1. Remove the-plunger lube fitting from each packing nut.
2. Using the SERVA packing nut tool, loosen each of the packing nuts at least one
full turn.
3. Remove the suction covers as outlined earlier in “To Remove Valves & Seats”.
4. Using the SERVA plunger wrench, unscrew the plunger from the crosshead and
pull each plunger out of the fluid cylinder through the suction cover bore. Care
must be taken to keep contaminants from entering the power end section once
the plunger is removed.
5. After securing the seal ring with the SERVA seal ring retainer or another suitable
tool, completely remove each packing nut from the packing gland thread bore.
The seal ring must remain in the cylinder while the packing nut is being
removed. Once the packing nut is removed, the seal ring may then be removed
from the cylinder. Label each packing nut on removal to ensure that they are
installed back into the same bore.
6. Inspect each plunger for wear, scoring, and corrosion on the hard surface area
and damage to the face which mates with the crosshead.
7. Inspect each ring of packing brass for excessive wear and scoring.
8. Blow air through the lube port on each packing nut to ensure that the lube
passage is unobstructed.
9. Each packing bore, both inside the packing nut and inside the fluid cylinder,
must be thoroughly cleaned and lightly hand polished with a 220 to 240 grit
emory cloth prior to packing reinstallation.
10. Using new packing header rings and new packing pressure rings, reinstall the
packing assembly one piece at a time (refer to the Packing Assembly diagram
included in this manual). Each ring should be installed with a coating of light oil
only. Care must be taken to avoid damaging the internal and external sealing lips
of each packing ring.
11. Replace the o-rings and back-up rings in the seal rings and dress the seal ring
seal areas in both the fluid cylinder and packing nut with 220 to 240 grit emory
cloth. Reinstall the seal ring as shown in the packing assembly diagram.
12. Reinstall each packing nut into its proper cylinder, screwing it all the way in
until tight, then backing it off one to two turns.
13. Coat the hard surface area of each plunger with a light oil and insert it into the
packing. Using an aluminium bar and 12 lb. hammer, bump the plunger into the
packing while holding it as straight as possible with the packing bore centreline.
Continue bumping the plunger through the packing until the threaded bore
approaches the crosshead stud; or for solid studded plungers, until the stud
approaches the crosshead threads. Carefully align the plunger and crosshead and
gently bump the plunger up against the crosshead.
- - 34 - -

B. To Change Plungers and Packing:
14. Tighten the plunger to the crosshead with the SERVA plunger wrench to achieve
torque as shown in the installation illustrations.
15. Using the SERVA packing nut wrench, packing tighten each nut as tight as
possible.
NOTE: The packing nut will need to be retightened only once after the pump is
reassembled and ran under pressure for a few revolutions. After that, the packing
is completely self-adjusting.
16. Reinstall the packing lube fitting into the packing nut.
17. Reinstall the suction covers as outlined earlier in “To Remove Valves and
Seats”.
C. To Remove Discharge Flanges:
1. Using a 1 5/8” wrench, remove the four V nuts from each of the two discharge
flanges.
2. Remove each discharge flange from the fluid cylinder. Remove the fluid seals
from both the inlet side and outlet side of each discharge flange. Closely inspect
each discharge flange for internal erosion and corrosion. Inspect the discharge
flange threads for wear and damage. The discharge flange seal surfaces should
be thoroughly cleaned and lightly hand polished with a 220 to 240 grit emory
cloth prior to reinstallation.
3. Inspect the fluid cylinder discharge flange bores for erosion and corrosion.
Thoroughly clean and lightly hand polish each bore with a 220 to 240 grit emory
cloth prior to reinstalling the discharge flanges.
4. Using new fluid seals and a coating of light oil, reinstall each discharge flange
being careful to avoid damaging the seal on the inlet side of the flange. Reinstall
the four V hex nuts on each flange and evenly tighten them to the proper torque
(refer to the Torque Table included in this manual).
- - 35 - -
D. To Remove the Suction Manifold:
1. Using a 11/8" wrench, remove the twelve 3/4" capscrews which secure the
suction manifold to the fluid cylinder, and drop the suction manifold away from
the fluid cylinder.
2. Inspect the suction manifold for internal erosion and corrosion. Remove the
three suction manifold o-ring seals and inspect the seal grooves in the manifold
for erosion and corrosion. Inspect the face and O.D. of the pipe at each end of
the manifold for erosion and corrosion. Note: The SERVA manifold incorporates
a Victaulic “ES” type connection at each end which will accept either a Victaulic
"End Seal Cut Groove" gasket or a Victaulic “Standard Cut Groove” gasket. The
condition of the pipe face at each end of the manifold is important for sealing
purposes only when the "End Seal (ES)" gasket is used.
3. Inspect the bottom face of the fluid cylinder for erosion and corrosion.
Thoroughly clean and lightly hand polish the bottom face of the fluid cylinder
with a 220 to 240 grit emory cloth prior to reinstalling the suction manifold.
4. Using new o-ring seals, reinstall the suction manifold. Reinstall the twelve 3/4"
capscrews and evenly tighten them to the proper torque (refer to the Torque
Table included in this manual).
E. To Remove The Fluid End:
1. Disconnect the plunger from the crosshead using the SERVA plunger wrench as
outlined earlier in Section B "To Change Plunger and Packing".
2. Disconnect the plunger lube hoses and whatever discharge piping connections
and suction piping connections are necessary for fluid end removal.
3. Remove the four (4) 1” bolts & the four (4) 1 3/8” bolts which secure the fluid
cylinder to the power end. Remove the fluid cylinder from the power end. *Note
that the fluid cylinder is only secured by these 8 bolts and must be supported
before the bolts are removed.
4. Examine the mating surfaces of the fluid cylinder and nose plate for signs of
damage. Examine mounting bolt threads for signs of damage. Repair or replace
as necessary.
5. Clean and lubricate the fluid cylinder mounting bolt threads, and hand tighten
the (8) bolts. Using a torque wrench, tighten the four (4) 1” bolts to 500 ft-lbs,
and the four (4) 1 3/8” bolts to 1300 ft-lbs.
6. Reconnect all hose and piping connections and tighten plunger to crosshead to
torque of 250 to 350 ft-lbs.
- - 36 - -
POWER END REPAIR PROCEDURES

Due to the complexity of the task and the need for special tools and training, SERVA
does not recommend the complete disassembly of the TPB/C/D600 power end or
speed reducer in the field. If extensive power end repairs are required, the pump
should be returned to the SERVA plant where expert service can be obtained on an
expedited emergency basis if needed. When field repairs are required, they should be
performed in a clean well equipped shop by a trained well service pump technician,
and should follow the guidelines below:
A. To Remove and Disassemble the Speed Reducer:
The TPB/C/D600 Speed Reducer assembly may be removed from the power end
without being disassembled by using a 1 7/16” wrench to remove the eight 7/8” hex
nuts which secure the speed reducer to the power end. SERVA highly recommends
removing the speed reducer intact when at all possible. When speed reducer internal
repairs are required, follow the procedure below to inspect or replace the bull gear,
pinion shaft, or roller bearings:
1. Remove the unit's mechanical driveline from the pump's input shaft.
2. Remove the power end rear cover and disconnect the lube line to the outboard
main bearing.
3. Remove the lubrication hoses from the speed reducer and remove the speed
reducer as a complete assembly from the power end. Lay the speed reducer
down on its mounting flange face with the input shaft facing up.
4. Using a 1 1/2” wrench, remove the 1” capscrew which secures the splined
companion flange to the input shaft. Remove the companion flange and inspect
it for wear.
5. Using a 3/4” wrench, remove the eight 1/2” capscrews which hold the pinion
seal retainer to the speed reducer housing. Remove the pinion seal retainer and
shims from the speed reducer, remove the oil seal from the retainer, and scrape
all old silicone sealer from the retainer.
6. Using a punch and hammer, drive the three 3/4” dowel pins from the outer
flange of the speed reducer housing. Using a 3/4” wrench, remove the
twenty-four 1/2” capscrews, nuts, and washers which secure the speed reducer
cover plate to the housing. Remove the eight 1/2” capscrews which secures the
bearing cover to the speed reducer. Remove the bearing cover and shims. Lift
the cover plate away. Scrape all old silicone sealer from the speed reducer cover
and from the flange on the housing. Using a brass punch and hammer, drive both
bearing cups (outer races) from the cover plate and inspect them for wear or
damage.
- - 37 - -

A. To Remove and Disassemble the Speed Reducer:
7. Remove the pinion shaft from the speed reducer and inspect both tapered roller
bearing cones for wear and damage. If the bearing cones need to be removed
from the shaft, do so by carefully heating them with an acetylene torch until they
will slip off the shaft. Care must be taken to avoid overheating the shaft itself.
Inspect the shaft for wear and damage to the gear teeth, seal surface, and bearing
journals.
8. Remove the bull gear from the pump and inspect the gear teeth and both tapered
roller bearing cones for wear and damage.
9. Using a 3/4" wrench, remove the eight 1/2" capscrews which hold the rear
pinion bearing cap on the speed reducer housing. Remove the bearing cap and
scrape all old silicone sealer from it.
10. Turn the speed reducer housing over on the opposite face. Using a brass punch
and hammer, drive the tapered roller bearing cups (outer races) out of the speed
reducer housing and inspect them for wear and damage.
11. Reassembly of the speed reducer should be performed in the reverse order of the
disassembly instructions above. Installation of new tapered roller bearing cones
on the pinion shaft or bull gear can be performed by pressing them on or by
heating the cone assembly thru any one of several methods. A temperature
controlled heating plate, hot oil bath unit, hot air cabinet, or induction heating
unit can be used to safely heat the bearings. When heating a bearing for
installation, the temperature must not exceed 250 degrees Fahrenheit (121
degrees Celsius). Installation of new tapered roller bearing cups in the housing
should be performed by tapping them into the housing with a soft metal bar or
by pressing them into the housing.
Upon reinstallation the bull gear and pinion shaft, it is extremely important to
establish the proper bearing “pre-load” (0.006" to 0.010") before operating the
pump. This must be accomplished by obtaining end play readings with a dial
indicator and removing the appropriate thickness of bearing adjustment shims.
Silicone liquid gasket material should not be applied to the bearing retainers
until after the bearing pre-load has been set properly. When reinstalling the
pump driveline hub on the input shaft, care must be taken to avoid overheating
and damaging the pinion oil seal.
B. To Remove the Crankshaft, Connecting Rods, and Crossheads:

1. Remove the speed reducer assembly as outlined previously.
2. Remove the plunger and seal retainers, as outlined previously.
3. Using a 9/16” wrench, remove the 3/8” capscrews which secure the side covers
and rear cover to the power end housing.
- - 38 - -

B. To Remove the Crankshaft, Connecting Rods, and Crossheads:
4. Remove the l/8” cotter pin from each of the twelve connecting rod bolts. Using a
15/16” wrench, remove the slotted 5/8” hex nuts from each of the twelve
connecting rod bolts. Remove the three connecting rod caps taking care to avoid
damaging the rod bearing half trapped inside each cap. Shove each connecting
rod/crosshead assembly all the way forward taking care to avoid damaging the
rod bearing half trapped inside each connecting rod.
5. Using a 3/4" wrench, remove the 1/2” capscrews which secure the wrist pin
retainer plate to the crosshead or using a 9/16" wrench, remove the 3/8”
capscrews which secure the wrist pin retainer washers to the wrist pin. Using a
slide hammer with 1”-11 1/2 LPT puller thread, pull the wrist pin from the
crosshead. Remove the connecting rod from the crosshead and take it out of the
power end. Rotate the crosshead 90 degrees and remove it thru the side of the
power end. Remove the other two connecting rods and crossheads in the same
manner.
6. Reattach each match-marked connecting rod cap to the rod from which it was
removed. Note: If the connecting rod bearing halves are to be removed and
re-used, they must be tagged so that they can be reinstalled in the same
connecting rod or cap.
7. Using a 9/16” wrench, remove the 3/8” capscrews which secure the tack drive
housing to the power end. Remove the tack drive assembly.
8. Using a 9/16” wrench, disconnect the lube oil hose which is attached to the main
bearing housing inside the power end. Using a 17/16” wrench, remove the eight
7/8” nuts which secure the main bearing housing to the power end. Remove the
main bearing housing and inspect the bearing for wear.
9. Turn the power end housing over on its side so that the crankshaft extension is
pointed straight up. The power end must be blocked up so that it rests level.
Using a 9/16” wrench, remove the 3/8” capscrews which secure the three
bearing retainers against the left hand inner main bearing's outer race. Lift the
crankshaft from the power end.
10. Using a 9/16” wrench, disconnect all six lube oil hoses from the fittings at the
rear of each crosshead guide. Using a 15/16” wrench, remove the two 5/8”
capscrews which secure each crosshead guide to the power end housing.
Remove all six crosshead guides and inspect them for wear.
11. Reassembly of the power end should be performed in the reverse order of the
disassembly instructions shown above.
- - 39 - -

NOTE: Prior to reassembling the power end, all lubrication hoses and lube passages
should be flushed and cleaned thoroughly.
When reinstalling the crosshead slides, care must be taken to avoid torquing the 5/8”
capscrews to more than 35 ft-lbs. torque. Excessive torque can distort the surface of
the slide causing crosshead misalignment.
The clearance between the top of the crosshead and top crosshead slide should be
checked with the feeler gauge from the side opening of the power frame (not from the
rear of the power frame). Clearance between the top crosshead slide and the crosshead
should be between 0.008-0.012”. If this clearance is not present, the bottom slide
should be removed and appropriate shims inserted between the slide and the power
frame at both the front and rear slide mounts.
When reinstalling the crankshaft, care must be taken to shim the left hand fixed type
inner main bearing so that it has only 0.003" to 0.015” lateral movement. Care must
also be taken to shim the main bearing housing and speed reducer in order to maintain
0.015” to 0.100” lateral running clearance on the two outer main bearings.
All capscrews, nuts, etc. must be torqued properly upon reassembly (see Torque Table
included in this manual).
- - 40 - -
TORQUE TABLE
CAPSCREWS9 NUTS & ALLOY STEEL STUDS &

BOLTS SAE GRADE 5 NUTS SAE GRADE 7
THREAD DIA. DRY LUBRICATED DRY LUBRICATED
& THREAD THREADS THDS. THREADS THDS.
PITCH TORQUE TORQUE TORQUE (FT. TORQUE (FT.
(FT. LBS.) (FT. LBS.) LBS.) LBS.)
1/4”-20 UNC 6.7 5.1 -- --
5/16”-18 UNC 13.9 10.4 -- --
3/8”-16 UNC 24.7 16.5 -- --
7/16”-14 UNC 39.4 29.6 -- --
1/2”-13 UNC 60.3 45.2 -- --
5/8”-11 UNC 110.0 80.0 -- --
3/4”-10 UNC 212.0 159.0 -- --
7/8”-9 UNC 315.0 .236.0 425.0 318.0
1”-8 UNC 472.0 354.0 635.0 477.0
1 1/8”-7 UNC 633.0 475.0 900.0 675.0
1 1/4”-7 900.0 675.0 1270.0 955.0
1 3/8”-8 NS -- --- 1660.0 1245.0
1 5/8”-8 NS --- --- --- 2300.0
1 3/4”-8 NS --- --- --- 2400.0
To obtain the required torque on the 1 3/8”, 1 5/8”, and 1 3/4” studs, when a torque
wrench is not available, use a hammer lug wrench. After tightening with a standard
wrench, turn the nut another 30 degrees (l/ 12th turn) with the hammer wrench.
- - 41 - -
Part List
Power End Parts
- - 42 - -
- - 43 - -
Item Part No. Qty Description

P61-11-000 POWER END,CASE ASSY
0001 P61-11-001 1 FRAME,MACHINING,POWER END
0002 P60-11-002 1 PLUG,BOTTOM COVER 3"NPT
0005 P60-11-005 1 COVER,TOP
0006 P60-11-006 1 COVER,BOTTOM
0007 P60-11-010 1 REAR COVER ASSY
0008 P60-11-008 1 GASKET,REAR COVER
0009 P60-11-009 1 OIL BREATHER
0010 X20-08-052 56 HHCS,.375-16UNCx1.000",GR 8,PLATED
0011 X20-27-552 56 WASHER,FLAT,3/8",ZINC PLATED
0014 P60-11-014 2 GASKET,TOP/BOTTOM COVER
0015 P60-11-015 2 FOOT PAD COVER
0017 X20-07-513 4 FHSCS,.250"-20UNCx0.50" LONG
0018 P60-11-018 1 FRONT FOOT-L/H
0019 P60-11-019 4 HHCS,.875-9UNCx1.50"LG,GR8
0020 P60-11-020 4 SET SCREW,SOCKET CAP HEAD,7/8"-9UNCx0.88"LG
0021 P60-11-017 1 FRONT FOOT-L/H
0023 X20-27-637 4 SEA FLAT WASHER,7/8",PLAIN
0024 X20-28-515 4 LOCKWASHER SPLIT, 7/8"
- - 44 - -
- - 45 - -

CRANKSHAFT ASSY,WITH HEAVY DUTY BEARING,WITH
P61-12-001
OIL HOLE
0001 P60-12-014 1.0000 CRANKSHAFT(WITH OIL HOLE)
0002 P61-12-002 1.0000 OUTSIDE BEARING HOUSING
0003 P60-12-027 6.0000 BEARING RACE RETAINER - OUTER
0004 P60-12-028 6.0000 BEARING RACE RETAINER - INNER
0005 P60-12-005 2.0000 OUTSIDE BEARING HOUSING GASKET
0006 P60-12-006 42.0000 SHIM,BEARING RACE RETAINER - OUTER
0007 P60-12-024 2.0000 BEARING,MAIN,OUTSIDE,FIXED,HEAVY DUTY
0008 P60-12-025 1.0000 BEARING,MAIN,INSIDE FIXED,HEAVY DUTY
0009 P60-12-026 1.0000 BEARING,MAIN,OUTSIDE FIXED,HEAVY DUTY
0010 P60-12-010 16.0000 STUD
0011 X20-22-909 16.0000 NUT,HEX,7/8"-9UNC
0012 X20-27-637 16.0000 SEA FLAT WASHER,7/8",PLAIN
0013 P60-12-013 24.0000 HHCS,.375-16UNCX0.88" LG -DRILLED
0014 X00-00-150 12.0000 WIRE,SAFETY,.051 OD,STAINLESS STEEL
0015 P60-12-015 24.0000 SHIM,BEARING RACE RETAINER - INNER
0016 P60-12-016 8.0000 SHIM,BEARING RACE RETAINER - INNER,0.04" THICK
0017 P60-12-017 8.0000 SHIM,BEARING RACE RETAINER - INNER,0.02" THICK
0018 P61-12-005 2.0000 OUTSIDE BEARING HOUSING GASKET 2.0MM
0019 X20-28-509 4.0000 WASHER,LOCK,5/16"
0020 X20-08-576 4.0000 HHCS,5/16"-18UN 1"LONG SAE GRADE 5
0023 P61-12-004 1.0000 INJUCTOR,OIL,CRANKSHAFT
0024 P15-08-031 1.0000 RING,RETAINING-N5000 156 H
0025 P15-09-031 1.0000 GASKET,INJUCTOR,CRANKSHAFT,OIL W/#20 ADAPTER
0026 P15-04-031 1.0000 RING,SEAL
BUSHING,MAGNETIC,SEAL INSULATOR & COUNTER
0027 P15-03-031 1.0000
DRIVE
0030 P15-05-031 1.0000 SEAL,MAGNETIC,SHAFT,MSC,65152 REV B
0031 000P569120 1.0000 O-RING,NITRILE 90 DURO #120,PEROXIDE CURED
0032 000P569126 1.0000 O-RING,NITRILE 90 DURO #126,PEROXIDE CURED
- - 46 - -
- - 47 - -

P61-13-001 CROSSHEAD CONNECTING ROD ASSY
0001 P60-13-001 3 CONNECTING ROD
0002 P61-13-004 3 CROSSHEAD,
0003 P61-13-003 6 CROSSHEAD GUIDE
0004 P60-13-004 3 CROSSHEAD WRIST PIN - SHORT
0005 X22-01-026 3 RETAINER,RING,GB893.1-86 90ID
0006 X04-02-012 12 PIN,COTTER,3.2x26 GB91-86
0007 P60-13-007 3 CONNECTING ROD BEARING
0011 P60-13-011 12 HHCS,.625-11UNCx4.00"LG - DRILLED
0015 X00-00-150 6 WIRE,SAFETY,.051 OD,STAINLESS STEEL
0017 P60-13-017 3 PLUG,SOCKET PIPE,1"-11-1/2 TPI
0018 P60-13-018 3 THRUST WASHER
0019 X20-07-513 3 FHSCS,.250"-20UNCx0.50" LONG
0020 P60-34-014 3 PLUNGER STUD
0021 P60-13-006 3 WRIST PIN BEARING
0022 P60-13-012 12 HHCS,.625-11UNCx5.00" LG ,SAE GRADE 8,MODIFIED
0023 P60-13-013 12 SLOTTED HEX NUT,5/8"-11NC
0024 P60-13-019 6 CONNECTION PIN
- - 48 - -
- - 49 - -

P61-14-000 GEAR REDUCER ASSY
0002 P60-14-002 2 COVER GASKET
0003 P60-14-003 1 LUBE OIL COVER
0004 P60-14-004 1 COVER
0005 P60-14-100 2 BEARING,SMALL,ASSY
0006* P61-14-200 1 CASE ASSY,MACHINED
0033 P60-14-201 3 PIN
0030 X20-08-850 19 HHCS,.500-13UNCx2",GR 8,PLATED
0031 X20-20-003 19 NUT,HEX,1/2-13"NC
0032 V06-50-322 19 WASHER,SPRING LOCK,STEEL,1/2"ID
0007 P60-14-005 1 BULL GEAR
0008 P60-14-006 4 PLUG,SOCKET PIPE,1/8"NPT
0009 P60-14-007 6 PIPE PLUG,2"NPT,SQ.END
0010 P60-14-008 0 PIPE PLUG,2"NPT,HEX
0012 P60-14-010 1 BEARING COVER
0013 P60-14-011 3 SHIM SET-12",0.7mm THICK
0015 V06-50-322 24 WASHER,SPRING LOCK,STEEL,1/2"ID
0016 P60-14-013 1 RETAINER
0017 P60-14-014 1 SHIM SET-8"
0018 P60-14-015 1 FLANGE,COMPANION,SPICER 1800 SERIES,6-1/2-1-741
0019 P60-14-016 1 RET. WASHER
0020 X20-08-598 1 BOLT,HEX,1"-14NSx1.5"LG
0021 X20-28-522 1 WASHER,LOCK,1"
0022 P60-14-300 1 SEAL ASSEMBLY
0023 P60-14-019 1 SPACER
0024 P60-14-020 1 PINION
0025 P60-14-400 2 BULL GEAR BEARING ASSY
0027 X20-28-507 4 WASHER,LOCK,3/8"
0028 P60-14-012 3 SHIM SET-12",0.2mm THICK
*When use TPD600 pump
0006 P61-14-200 1 CASE ASSY,MACHINED
- - 50 - -
FLUID END PARTS
- - 51 - -
- - 52 - -
2 3/4” Fluid End Assy:

P60-27-000 FLUID-END,2 3/4"
0001 P60-30-105 6 DISCHARGE COVER SEAL,2.875 X 3.5 X 0.344
0002 P60-30-103 1 DISCHARGE COVER W/2" 1502 F
0003 P60-34-104 1 SEAL RING,2",FIG 1502
0004* P60-30-200 2 DISCHARGE FLANGE ASSY
0004a* P60-30-201 1 DISCHARGE FLANGE
0004b P60-34-206 1 SEAL,POLYPAK
0004c 000P569235 1 O-RING,NITRILE 90 DURO #235,PEROXIDE CURED
0004d P60-34-214 4 HHN,1"-8NC,L7
0004e P60-34-215 4 STUD,1"-8NCx3 1/2",L7 FULL STUD
0004f P60-34-104 1 SEAL RING,2",FIG 1502
0005 P60-34-311 1 MANIFOLD
0006 X20-08-010 12 HHCS,.750-10UNCx1.5",GR8,PLATED
0007 P60-30-401 2 DISCHARGE COVER
0008 P60-30-004 3 VALVE SPRING
0009 P60-30-005 1 FLUID CYLINDER,3"
0010 P60-27-006 3 PLUNGER,2 3/4"
0011 P8T0005275 3 PACKING,SPS,ASSY,3.000
0012 P60-30-007 3 SUCTION VALVE STOP
0013 P60-30-600 6 VALVE ASSY
0015 P60-30-008 6 SEAT,VALVE
0016 000P569244 3 O-RING,NITRILE 90 DURO #244,PEROXIDE CURED
0018 P60-30-702 3 BACK-UP,TEFLON,AS568-233,
0019 P60-30-701 3 SUCTION COVER
0020 P60-30-011 5 SUCTION COVER RETAINER NUT
0021 P60-34-012 4 SCREW,TPFS,1"-12UNx11.00"LG
0022 P60-34-013 4 SCREW,TPFS,1-3/8"-12UNx10.50"LG
0023 P60-27-800 3 SEAL,SET,ASSY
0025 P60-27-502 3 NUT,PACKING,2 3/4"
0026 X26-02-009 24 PLUG,PIPE,1/4"-18NPT,HEX SOCKET,PLATED
* When use the longer discharge flange:
0004 P61-34-200 2 DISCHARGE FLANGE ASSY
0004a P61-34-201 1 DISCHARGE FLANGE
- - 53 - -
3” Fluid End Assy:

P60-30-000 FLUID-END,3"
0001 P60-30-105 6 DISCHARGE COVER SEAL,2.875 X 3.5 X 0.344
0003 P60-34-104 1 SEAL RING,2",FIG 1502
0004a* P60-30-201 1 DISCHARGE FLANGE
0004d P60-34-214 4 HHN,1"-8NC,L7
0004f P60-34-104 1 SEAL RING,2",FIG 1502
0005 P60-34-311 1 MANIFOLD
0009 P60-30-005 1 FLUID CYLINDER,3"

0010 P60-30-006 3 PLUNGER,3"
0013 P60-30-600 6 VALVE ASSY
0015 P60-30-008 6 SEAT,VALVE
BACK-UP,TEFLON,AS568-233,2.880"x0.048-0.052"THx0
0018 P60-30-702 3
.118-0.120"W
SCREW,TPFS,1"-12UNx11.00"LG,HIGH TORQUE
0021 P60-34-012 4
FLANGE,GRADE 120M,ROLLED THREADS
SCREW,TPFS,1-3/8"-12UNx10.50"LG,HIGH TORQUE
0022 P60-34-013 4
0023 P60-30-800 3 SEAL,SET,ASSY
0025 P06-00-060 3 NUT,PACKING,3"
PLUG,PIPE,1/4"-18NPT,HEX SOCKET,PLATED(SAME
0026 X26-02-009 24
PART WITH V06-37-872)
* When use the longer discharge flange:
- - 54 - -
3 1/2” Fluid End Assy:

P60-34-000 FLUID-END,3 1/2",ASSY
0001 P60-34-105 3 DISCHARGE COVER SEAL
0003 P60-34-104 1 SEAL RING,2",FIG 1502
0004a* P61-34-201 1 DISCHARGE FLANGE, W/2" FIG 1502 F
0004d P60-34-214 4 HHN,1"-8NC,L7
0004f P60-34-104 1 SEAL RING,2",FIG 1502
0005 P60-34-311 1 MANIFOLD
0009 P60-34-005 1 FLUID CYLINDER,3-1/2" TO 4-1/2"
0010 P60-34-006 3 PLUNGER,3 1/2"
0013 P60-34-600 6 VALVE ASSY
0015 P60-34-008 6 VALVE SEAT,3 1/2",4" & 4-1/2"
0018 P60-34-704 3 SUCTION COVER SEAL
0021 P60-34-012 4
0022 P60-34-013 4
0023 P60-34-820 3 SEAL,SET,ASSY
0025 P06-00-063 3 NUT,PACKING,3-1/2"
0026 X26-02-009 24
* When use the shorter discharge flange:
- - 55 - -
4”Fluid End Assy:

P60-40-000 FLUID-END,4"
0003 P60-34-104 1 SEAL RING,2",FIG 1502
0004d P60-34-214 4 HHN,1"-8NC,L7
0004f P60-34-104 1 SEAL RING,2",FIG 1502
0005 P60-34-311 1 MANIFOLD
VALVE SPRING,4"FLUID END,DISCHARGE(SPM
0008 P60-40-004 3
TWS600S)
0010 P60-40-006 3 PLUNGER,4"
0013 P60-34-600 6 VALVE ASSY
0015 P60-34-008 6 VALVE SEAT,3 1/2",4" & 4-1/2"

0021 P60-34-012 4
0022 P60-34-013 4
0023 P60-40-820 3 SEAL,SET,ASSY
0025 P06-00-065 3 NUT,PACKING,4"
0026 X26-02-009 24
- - 56 - -
4 1/2”Fluid End Assy:

P60-44-000 FLUID-END,4 1/2"
0003 P60-34-104 1 SEAL RING,2",FIG 1502
0004d P60-34-214 4 HHN,1"-8NC,L7
0004f P60-34-104 1 SEAL RING,2",FIG 1502
0005 P60-34-311 1 MANIFOLD

0010 P60-44-006 3 PLUNGER,4 1/2"
0013 P60-34-600 6 VALVE ASSY
0015 P60-34-008 6 VALVE SEAT,3 1/2",4" & 4-1/2"

0021 P60-34-012 4
0022 P60-34-013 4
0023 P60-44-820 3 SEAL,SET,ASSY
0025 P06-00-058 3 NUT,PACKING,4-1/2"
0026 X26-02-009 24
- - 57 - -
Packing Assembly 3”:

P8T0005300 PACKING,SPS,ASSY,3.000
0001 P06-00-061 1 RING,SEAL,3"
0002 000PBUN239 1 BACKUP,O-RING,90 DURO,#239
0006 P902503000 1 PACKING,SPS,HEADER RING,3.000x4.000
0007 P903503000 1 PACKING,SPS,VD RING,3.000x4.000
0008 P904503000 1 PACKING,SPS,FEMALE ADAPTER,3.000x4.000
0009 P833000790 1 PACKING,SPS,LANTERN RING,3.000x4.000x0.790
0010 P06-00-060 0 NUT,PACKING,3"
0011 P906503000 1 PACKING,SPS,OL SEAL,3.000x3.500x0.275
0050 P8A0005300 0 PACKING,SPS,REPAIR KIT A,3.000
Packing Assembly 3 1/2”:

0001 P06-00-064 1 RING,SEAL,3-1/2"
- - 58 - -

0010 P06-00-063 0 NUT,PACKING,3-1/2"
0012 P06-00-077 1 SPACER,STEEL,4.5"X5.5"
Packing Assembly 4”:

0001 P06-00-066 1 RING,SEAL,4"
0010 P06-00-065 0 NUT,PACKING,4"
Packing Assembly 4 1/2”:

0001 P06-00-059 1 RING,SEAL,4-1/2"
0010 P06-00-058 0 NUT,PACKING,4-1/2"
- - 59 - -
This is an old style set seal assembly before 2007.

Item Part No. Part No. Part No. Part No. Qty Description
3" 3 1/2" 4" 4 1/2" PLUNGER DIA.
Assy P60-30-800 P60-34-800 P60-40-800 P60-44-800 SEAL,SET,ASSY
0001 P60-30-803 P60-34-801 P60-40-801 P60-44-801 1 DIAPHRAGM OIL SEAL
0002 P60-30-801 P60-34-802 P60-40-802 P60-44-802 1 DEFLECTOR
0003 P60-30-802 P60-34-803 P60-40-803 P60-44-803 1 DIAPHRAGM PLATE
0004 P60-34-804 P60-34-804 P60-34-804 P60-34-804 1 DIAPHRAGM PLATE GASKET
0005 000P569343 000P569346 000P569351 000P569354 1 O-RING
0006 P60-30-804 P60-34-809 P60-40-809 P60-44-809 1 WASHER RING
0007 X20-28-003 X20-28-003 X20-28-003 X20-28-003 4 LOCKWASHER,SPLIT 1/4"
0008 X20-08-007 X20-08-007 X20-08-007 X20-08-007 4 HHCS,.25"-20UNCx0.625",GR 8,PLATED
0009 X20-08-044 X20-08-044 X20-08-044 X20-08-044 4 HHCS,.375-16UNCx0.750",GR 8,PLATED
- - 60 - -
This is a latest style set seal assembly since 2007,3" no change.

Item Part No. Part No. Part No. Qty Description
3 1/2" 4" 4 1/2" PLUNGER DIA.
ASSY P60-34-820 P60-40-820 P60-44-820 SEAL,SET,ASSY
0001 P60-34-807 P60-40-806 P60-44-806 1 DIAPHRAGM PLATE
0002 P60-34-804 P60-34-804 P60-34-804 1 DIAPHRAGM PLATE GASKET
0003 P60-34-816 P60-40-816 P60-44-817 1 DIAPHRAGM OIL SEAL
0004 P60-40-805 P60-40-805 P60-40-805 4 DIAPHRAGM SCREW
0005 P60-34-808 P60-40-808 P60-44-805 1 DEFLECTOR HOUSING
0006 X20-08-052 X20-08-052 X20-08-052 3 HHCS,.375-16UNCx1.000",GR 8,PLATED
0007 000P569346 000P569351 000P569354 1 O-RING
0008 P60-34-810 P60-40-807 P60-44-807 1 DEFLECTOR SCRAPER -MODIFIED
0010 - - P60-44-818 2 WASHER PLATE, 5.200X5.49"X0.031"
note: P60-34-800,P60-40-800,P60-44-800 can be replaced by P60-34-820,
P60-40-820, P60-44-820
- - 61 - -
ACCESSORIES
- - 62 - -
P60-34-900 TOOL
0001 P60-34-910 1.0000 VALVE COVER REMOVAL TOOL,2"HEX
0002 P60-34-920 1.0000 SLIDE HAMMER
0003 P60-34-930 1.0000 PLUNGER WRENCH TOOL,1 1/2" SQUARE
0004 P60-34-940 1.0000 PACKING NUT TOOL,0.63
0005 P60-34-308 1.0000 VALVE LIFTER TOOL
0006* P60-34-926 0.0000 SEAT PULLER ASSY,LISTING(3 1/2",4"&4 1/2")
0007 P60-34-966 0.0000 SEAT PULLER ASSY,LISTING(3 1/2",4"&4 1/2")
0008 P60-30-901 0.0000 SEAT PULLER ASSY,LISTING(3")

* Item(0006,0007,0008) is an optional tool. If need, please order it except the pump.
- - 63 - -
- - 64 - -
- - 65 - -
- - 66 - -
- - 67 - -
- - 68 - -
- - 69 - -
VALVE SEAT PULLER ASSY
- - 70 - -

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SECTION Ⅱ - INSTALLATION DETAILS:

SECTION Ⅲ - PUMP OPERATION AND MAINTENANCE:

SECTION Ⅳ - PUMP PARTS INFORMATION:

Follow all of the following safety precautions when you operate a

1. Before you work on a 600 pump, check the following items:

Never place your hands in the fluid end, the area

Never use a full-close valve to build pressure in a positive-

protective guards are installed.

Section I BASIC INFORMATION

Optional packing assemblies, valve assemblies, discharge flanges, suction manifolds,

SERVA Model TPB/C/D600 PLUNGER PUMP

2 3/4” .46 23 16,836 56 16,665 93 9,999 139 6,666 208 4,444

3” .55 28 14,147 66 14,003 110 8,402 165 5,601 248 3,734

Installation Detail Drawing (TPB/D600)

Installation Detail Drawing (TPB/D600)

The nameplate contains information of pump type, Max.

pressure, plunger size, and Serial No.

Atmosphere G : Gases D: Dusts

Use in Zone 1 Zone 21

The Applicable standards and Technical specification:

EN13463-1 ; EN13463-5 & EN1127

TACH DRIVE/RATE METER CALIPRATION SPECICATIONS

NOTE: THE VOLUMETRIC EFFICIENCY AND RESULTING DISPLACEMENT WILL VARY

V.E. = VOLUMETRIC EFFICIENCY OF PUMP

USEFUL PUMP DATA FORMULAS

A ----------------- Area (sq. in.)

Parts General Information

Transmission Noise at Noise at Background Noise dB(A)

SHIPPING AND STORAGE

Section Ⅱ INSTALLATION DETAILS

POWER END LUBE SYSTEM REQUIREMENTS

operates at engine speed whenever the plunger pump’s prime mover is

3. Lube System Pressure Lines and Oil Filter:

4. Lube System Relief Valve and Relief Return Line:

RECOMMENDED POWER END LUBE OILS

1. General Service Lube Oils:

Amoco ........................................................................ Amogear MP90

RECOMMENDED POWER END LUBE OILS

3. Extreme Hot Weather Lube Oils:

Amoco ................................................................................ Amogear MP 140

PLUNGER LUBE SYSTEM REQUIREMENTS

2. In-Line Relief Valve:

3. Flow Control Needle Valves:

4. High Pressure Check Valves:

RECOMMENDED PLUNGER LUBE OILS

1. General Service (above 32 degrees Fahrenheit)

2. Extreme Cold Weather Service (below 32 degrees Fahrenheit):

RECOMMENDED PLUNGER LUBE OILS

TPB/C/D 600 STARTUP AND BREAK-IN PROCEDURE

A. Inspection Prior to Starting Engine:

TPB/C/D600 STARTUP AND BREAK-IN PROCEDURE

B. Warmup Procedure Prior to Rotating the Plunger Pump:

C. Plunger Pump Valve Seating Procedure:

TPB/C/D 600 STARTUP AND BREAK-IN PROCEDURE

TPB/C/D 600 STARTUP AND BREAK-IN PROCEDURE

Plunger Dia. Pump RPM GPMIBPM PSI BHP

TROUBLE SYMPTOM: PROBABLE CAUSE: