415Q5 Plunger Pump Operation Manual

415Q-5 PLUNGER PUMP
Operation Manual
CONTINUOUS DUTY SINGLE ACTING MULTIPLEX PLUNGER PUMP
Document Number Rev

415Q-5 OPMNL-001 C
This document contains proprietary and confidential information

which belongs to National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as “NOV”). It
is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted
without the express written consent of NOV. This document is to
be returned to NOV upon request and in any event upon
completion of the use for which it was loaned. This document
and the information contained and represented herein is the
copyrighted property of NOV. ©National Oilwell Varco
NATIONAL OILWELL VARCO

6750 South 57th West Ave
Tulsa, OK 74131
T: 918.447.4600
E: [email protected]
www.nov.com/pft
FOREWORD
This manual is published as a guide for the normal operation of your NATIONAL OILWELL VARCO
equipment. Because of the many factors, which contribute to the function or malfunction of this
machinery, and not having complete knowledge of each factor or combination of factors, we cannot
detail all facets of this subject. We must therefore confine the scope of this presentation and when
situations encountered are not fully encompassed by complete, understandable instructions, these
situations must be referred to the manufacturer.
When other than routine servicing is necessary, it can be most efficiently performed if the unit is
removed to an area of adequate space where an over-head crane, hydraulic lift, bearing pullers, impact
tools, etc., are accessible.
The dimension and tolerances specified in this publication are those desirable for the most efficient
operations of the equipment. When components become worn or when new parts are introduced into
a worn unit, it may not be possible or economically feasible to reestablish such strict alignment and
correct all dimensional deviations.
Improvements in design, engineering, materials, production methods, etc., may necessitate

changes in these products and result in inconsistencies between the content of this publication and the
physical equipment. We reserve the right to make these changes without incurring any liability or
obligation beyond that which is stipulated in the purchase contract.
The pictures, photographs, charts, diagrams, drawings, verbal contents and specifications are not to
be construed as giving rise to any warranty on the part of NATIONAL OILWELL VARCO. National Oilwell
Varco makes no warranty, either expressed or implied beyond that which is stipulated in the purchase
contract.
NATIONAL OILWELL VARCO pumps are manufactured by National Oilwell Varco at the Tulsa,
Oklahoma plant. The serial number, assigned to each pump, is stamped on the power end. Please
refer to this serial number when ordering parts for the pump.
The right and left sides of the pump are determined by viewing the pump from the back of the
power end, looking toward the fluid end. This position is also used to identify the plungers and their
related parts as being number one, two and three, etc. beginning at the left side of the pump.
[email protected] nov.com/pft
! CAUTION ! CAUTION ! CAUTION !
EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS; USE ONLY APPROVED
METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF
QUESTIONABLE SAFETY; ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY
IS YOUR BUSINESS AND YOU ARE INVOLVED.
! WARNING ! WARNING ! WARNING !

BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED
FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY
FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR
MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE
COMPRESSOR/AIR SYSTEM, ETC.
FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN
PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.
! ATTENTION - NOTICE - IMPORTANT !

THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP,
COMPONENTS OR ATTACHMENTS.
! ATTENTION !
PUMP NOMENCLATURE:

BEFORE SERVICING PUMPS:
1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE.
2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.
3. RELIEVE OR “BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S).
FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING
CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE.
TABLE OF CONTENTS
INSTALLATION 1
OPERATION CHECKLIST 6
MAINTENANCE 8
LUBRICATION 9
OVERHAUL AND REPAIR 11
DIASSEMBLY OF POWER END 12-31
REMOVAL OF WIPER BOX AND INTERMEDIATE RODS 12
REMOVAL OF CRANKCASE COVERS AND CONNECTING ROD CAPS 15
REMOVAL OF CONNECTING ROD AND CROSSHEADS 16
DISASSEMBLY AND REMOVAL OF GEAR REDUCER 18
REMOVAL OF CRANKSHAFT FROM POWER FRAME 21
DISASSEMBLY OF CRANKSHAFT 26
DISASSEMBLY OF WIPER BOX 27
DISASSEMBLY OF CONNECTING ROD 28
REMOVAL OF STUFFING BOX 32
DISASSEMBLY OF STUFFING BOX 34
SEPARATING THE POWER END FROM THE FLUID END 37
DISASSEMBLY OF MODELS “L” AND “M” FLUID ENDS 39-47
REMOVAL OF VALVE COVERS 39
REMOVAL OF SUCTION AND DISCHARGE VALVES WITH TAPERED VALVE SEATS 41
DISASSEMBLY OF “H” MODEL FLUID END 43-48
REMOVAL OF CAGED VALVE COVERS 43
REMOVAL OF CAGED VALVE ASSEMBY 44
ASSEMBLING THE POWER END 49-75
ASSEMBLING THE CONNECTING ROD AND CROSSHEAD 49
ASSEMBLING THE WIPER BOX 52
ASSEMBLING THE CRANKSHAFT 54
INSTALLATION OF MAIN BEARING RACES ON CRANKSHAFT 59
INSTALLATION OF TAPERED BEARINGS AND BEARING CAGE ON CRANKSHAFT 61
INSTALLATION OF MAIN BEARINGS IN POWER FRAME 64
INSTALLATION OF CONNECTING ROD AND CROSSHEAD IN POWER FRAME 67
INSTALLATION OF CRANKSHAFT 68
COMPLETION OF CONNECTING ROD ASSEMBLY ON CRANKSHAFT 70
COMPLETION OF CRANKSHAFT INSTALLATION 72
INSTALLATION OF WIPER BOX 74
FINAL POWER FRAME ASSEMBLY AND LUBRICATION 75
ASSEMBLING THE MODEL “L” AND “M’ FLUID ENDS 76-84
INSTALLATION OF SUCTION VALVE SEATS 76
INSTALLATION OF VALVE COMPONENTS 77
INSTALLATION OF DISCHARGE VALVE SEATS 79
INSTALLATION OF FLUID END STUDS AND COVERS 82
INSTALLATION OF FLUID END TO POWER FRAME STUDS 84
ASSEMBLING THE MODEL “H” FLUID END 86-95
INSTALLATION OF CAGED VALVE COMPONENTS 86
INSTALLATION OF VALVE COVER AND LOADING BOLT 93
INSTALLATION OF FLUID END TO POWER FRAME STUDS 95
MATING THE FLUID END TO POWER END 96
STUFFING BOX ASSEMBLY AND INSTALLATION 97-110
STUFFING BOX FOR BRAIDED PACKING 97
STUFFING BOX FOR 838 PACKING 102
INSTALLATION OF STUFFING BOX IN PUMP 109
INSTALLATION OF PLUNGER CLAMP 111
MOUNTING GEAR REDUCER AND FINAL ASSEMBLY 113-117
INSTALLATION OF GEAR REDUCER HOUSING 113
INSTALLATION OF GEAR SETS INTO GEAR REDUCER HOUSING 114
INSTALLATION OF POWER END COVERS 117
PLUNGER LUBRICATION SYSTEM SERVICE 118-122
ROCK DRILL OIL CHART 119
PACKING ADJUSTMENT 122
STORAGE AND RE-START AFTER STORAGE 123
TROUBLESHOOTING 124-126
PARTS LISTS AND GENERAL ARRANGEMENT DRAWINGS
POWER FRAME ASSEMBLY 1716888

CRANKSHAFT ASSEMBLY 1716889
CRANKSHAFT ASSEMBLY, DRIVE SIDE 1716890
CRANKSHAFT ASSEMBLY, ACCESSORY SIDE 1716891
CONNECTING ROD ASSEMBLY 1716892
WIPER BOX ASSEMBLY 1716893
INTERMEDIATE ROD AND PLUNGER CLAMP ASSEMBLY 1716894
STUFFING BOX ASSEMBLY, BRAIDED PACKING 1716895
STUFFING BOX ASSEMBLY, JFD PACKING 1716905
FLUID END ASSEMBLY, 415Q-5L 1716897
FLUID END ASSEMBLY, 415Q-5M 1716896
FLUID END ASSEMBLY, 415Q-5H 1716899
GEAR REDUCER ASSEMBLY 1716896
PLUNGER LUBRICATION SYSTEM 1716902
TAPERED VALVE ASSEMBLY, SPHERICAL AND SEVERE DUTY SPHERCIAL 1716904
CAGED VALVE ASSEMBLY, SPHERICAL AND SEVERE DUTY SPHERICAL 1716909
VALVE SEAT INSTALLATION KIT FOR TAPERED SEAT VALVES 1716906
VALVE SERVICE KIT FOR CAGED VALVES 1716907
VALVE SEAT REMOVAL KIT FOR TAPERED VALVE SEATS 1716908
GENERAL ARRANGEMENT, 415Q-5L WITHOUT GEAR REDUCER 1716882

GENERAL ARRANGEMENT, 415Q-5M WITHOUT GEAR REDUCER 1716883
GENERAL ARRANGEMENT, 415Q-5H WITHOUT GEAR REDUCER 1716884
GENERAL ARRANGEMENT, 415Q-5H WITH GEAR REDUCER 1716885
GENERAL ARRANGEMENT, 415Q 1716886
! CAUTION ! CAUTION ! CAUTION !
EXERCISE SAFETY IN ALL PERFORMANCES: DO NOT IGNORE ANY WARNINGS; USE ONLY APPROVED
METHODS, MATERIALS AND TOOLS. DO NOT PERMIT ANY FUNCTION OF
QUESTIONABLE SAFETY; ACCIDENTS ARE CAUSED BY UNSAFE ACTS AND UNSAFE CONDITIONS. SAFETY
IS YOUR BUSINESS AND YOU ARE INVOLVED.

BEFORE PERFORMING ANY SERVICE FUNCTION, BE CERTAIN THAT THE UNIT IS SEPARATED
FROM ITS POWER SOURCE OR THAT THE POWER SOURCE IS LOCKED-OUT TO PREVENT ANY
FORM OF ENERGY FROM ENTERING THE EQUIPMENT. THIS WOULD INCLUDE ELECTRICAL OR
MECHANICAL ENERGY INTO OR FROM THE PRIME MOVER(S), PNEUMATIC ENERGY FROM THE
COMPRESSOR/AIR SYSTEM, ETC.
FAILURE TO OBSERVE THE WARNINGS AND NOTES OF CAUTION IN THIS PUBLICATION CAN RESULT IN
PROPERTY DAMAGE, SERIOUS BODILY INJURY, OR DEATH.
! ATTENTION - NOTICE - IMPORTANT !

THESE TERMS ARE USED TO DRAW ATTENTION TO ACTION THAT WILL CAUSE DAMAGE TO THE PUMP,
COMPONENTS OR ATTACHMENTS.
! ATTENTION !
BEFORE SERVICING PUMPS:
1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE.
2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.
3. RELIEVE OR “BLEED OFF" ALL PRESSURE FROM THE PUMP FLUID CYLINDER(S).
FAILURE TO SHUT DOWN POWER AND RELIEVE PRESSURE FROM THE PUMP BEFORE SERVICING
CAN RESULT IN SERIOUS PERSONAL INJURY AND PROPERTY DAMAGE.
INSTALLATION
I. GENERAL
Careful planning of the plant layout will save considerable time and expense, both initially when the
installation is made and later during the operation of the pump. In selecting the location for the pump,
consideration should be given to the fact that a positive suction head at the pump inlet contributes toward the
pump efficiency. However, the layouts of the piping, the arrangement of the fittings, and restrictions in the
suction and discharge lines have even more effect. For this reason, all fittings and valves should be full opening;
all bends should be of long radius or should be eliminated where possible. Long radius 45° elbows should be
used, particularly if installed near the fluid cylinder. The following points outline the basic requirements for an
installation that will contribute greatly toward good pump operation.
A. LIFTING

Extreme care must be made when lifting this pump to avoid property damage, serious bodily injury, or death.
1. CHAIN SELECTION
Minimum chain specification is as follows:
3/8” size
31/32” pitch steel
Rated 5000# Proof Test
Use of chain below minimum requirements can result in damage, serious bodily injury, or death.
2. CHAIN LOCATIONS
The arrangement drawings on the following sheet indicate the proper slinging method for handling this
pump with chains. Any deviation from this plan can result in damage, serious bodily injury, or death.
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B. PUMP MOUNTING
1. The skid or foundation must be level. Angular installation and operation may be detrimental to the
lubrication of equipment and may impose high stresses causing equipment failure.
2. The skid or foundation must be of sufficient strength to prevent flexing of the equipment.
3. The skid or foundation must be of sufficient size and design to maintain the equipment free of strain.
4. The equipment must be adequately secured to the foundation. High strength bolts or cap screws with
locking devices are generally employed.
5. Consideration should be given to the location of the equipment with its proximity to the associated
equipment, fluid supply, fuel supply, environmental contamination, etc.
6. Avoid environmental contamination by providing the proper disposition of drainage from the crankcase,
gear case, chain case, sludge sump and any other lubrication reservoirs as well as from the flushing
media sump, the pump cradle, the suction line and the discharge line.
C. ALIGNMENT
1. It is most important that the pump be accurately aligned with the prime mover.
2. Follow the recommended alignment procedures provided by the manufacturer of the belts and sheaves
or couplings.
D. SUCTION LINE
1. The suction line must not be smaller than the suction intake of the fluid end and may be larger. The length
of the suction line should be held to a minimum and should run straight from the supply tank to the pump.
If a reducer is required in the suction line between the main line and pump, use an eccentric reducer
rather than a concentric reducer with straight portion on top to help avoid air pockets trapped in the
suction line.
2. When bends are required, they should be made with long radius 45° elbows. Do not use a bend directly
adjacent to the fluid end. Avoid using 90° if at all possible.
3. Provide a full opening gate valve in the suction line adjacent to the supply tank to permit the line to be
drained when necessary. Do not use any type of restricting valve.
4. Do not use meters or other restrictions in the suction line. Eliminate any rise or summit in the suction
line where air or vapor can collect.
5. Pulsation dampening devices are strongly recommended.

6. When necessary to manifold a number of pumps to a common suction, the diameter of the manifold
and suction pipe leading from the supply tank must be such that it has a cross-sectional area equal to,
or greater, than the area of the combined individual suction pipes.
7. When a charging or booster pump is used in the suction line, it must have a capacity equal to twice that
of the pump output. This is necessary to provide a charging pump with an output great enough to meet
the peak volume requirements of the plunger pump during the suction stroke and not act as a
restriction in the line.
8. All piping, both suction and discharge must be solidly and independently supported. The first support
must be as close to the pump as practical. This is necessary to prevent placing the pump in a strain and
to keep any vibration in the system from acting directly on the pump.
E. DISCHARGE LINE
1. Use a pulsation dampener or a desurger in the discharge line. It should be placed in the line as near the
fluid end as possible and ahead of any bend in the line.
2. Do not reduce the size of the discharge line below that of the pump outlet until the line has passed
through the desurger, and is away from the pump approximately 20 feet (6m).
3. Any bend in the discharge line should be made with a long radius 45° elbow. Do not use a bend directly
adjacent to the fluid cylinder, particularly a 90° bend.
4. A pressure relief valve should be installed in the discharge line. The relief valve should be set to operate
at a pressure no greater than 10% above the maximum rated pressure for the plunger size being used. It
should be installed in the line ahead of any valve and be piped so that any flow is returned to the supply
tank rather than the suction line. This will prevent possible damage to the suction line and suction
dampener.
5. A by-pass line should be installed to permit the pump to be started without load. This allows oil to
circulate and reach all parts in the power end before they are loaded.
F. POWER END
1. The pump must be mounted level and should be grouted in and be free of strain. This applies to a skid-
mounted pump or a pump mounted directly on a concrete base.
2. The sheave of a belt driven pump must be correctly aligned with the prime mover sheave. Care must be
used to prevent over-tightening as this will shorten belt life and cause undue additional loads on the
crankshaft and bearings. Sheave sizes should not be smaller than the minimum approved diameter.

3. When connecting a direct-driven pump, the shafts must be correctly aligned. Couplings should not be
expected to compensate for avoidable misalignment. With flexible shaft couplings, angular misalignment
should not exceed one-half degree. Offset misalignment of the centerlines of the two shafts should not
exceed .015" (.381 mm). Actually, misalignment should be as small as practical.
4. Provision should be made to stop the pump automatically in the event of supply fluid failure. A pump
should not be run dry, as this causes wear on the packing.
5. Adequate plunger chamber drains have been provided in the pump and should not be plugged. Drain
lines should never be reduced in size from the connection provided.
6. The pump has been drained of oil after testing at the factory and MUST be filled with the proper oil (see
Lubrication Section in this manual) before starting. The rust inhibiting oil coating inside the power end
need not be removed before filling; however, it is recommended that the power end be checked to make
sure dirt or contamination has not entered during shipment.
G. FLUID END
1. The fluid cylinder is shipped assembled to the pump complete with valves and covers. The stuffing
boxes, plungers, and related items have also been assembled and tested with the pump (unless
otherwise specified) and require no further assembly. Before the pump is started, these parts should
be checked for tightness as well as for possible damage during shipment.
2. Thoroughly clean the suction line piping before starting the pump. Weld spatter, slag, mill scale, etc., will
damage a pump in a short time.
H. PLUNGER PACKING
The recommended style of packing has been installed and run at the plant. It does, however, require further
"setting up" as the pump is started and brought up to pressure. Refer to the Assembly, Fluid End, Plunger
Packing Installation section of this manual for correct procedure for packing used.
I. PLUNGER PACKING LUBRICATION
1. Automatic packing lubricators are beneficial on all installations and are required on pumps operating at
high pressure (1200 psi [85kg/cm 2] and up) to obtain good packing life.
2. When an automatic lubricator is used in water and power oil service, use Rock Drill (Air Drill) oil of proper
viscosity. For butane-propane service, use NATURAL castor oil. Set lubricator to deliver the appropriate
amount of oil. A compete sheen of oil on the plunger must be visible. See Lubrication Table on page 119
of this manual.

! ATTENTION !

THE FOLLOWING POINTS SHOULD BE CHECKED FOR THE PREVENTION OF TROUBLE OR TO CORRECT
TROUBLE THAT MAY ARISE.

OPERATION CHECKLIST

1. Pump must be a set level for proper lubrication.

2. Make sure pump is filled with clean oil of the proper viscosity (see section on Lubrication).

3. Do not over‐speed the pump.

4. Do not use a smaller diameter sheave than is recommended for the pump.

5. Make sure all safety shutdown switches are operating properly.

6. Keep all suction and discharge line valves fully open.

7. If a bypass is used to regulate output, make sure it is set properly.

8. Make sure the pressure relief valve is set properly.

9. Do not exceed the pressure rating of the pump for the particular plunger size.

10. Make sure the suction line is tight, as air entering the suction line will cause severe hammering and
knocking of the pump.

11. Make sure plunger and intermediate rod connections are tight and locked.

12. Check the plunger packing for correct adjustment (see page 122).

13. Check the suction and discharge dampeners for proper charge, as this is very important for long life and
good pump operation.

14. Make sure the hex nuts holding the cylinder in place are tight.


PERFORMANCE CHART


MAINTENANCE

The following points are intended to be a guide to be used in setting up a maintenance program. Good
preventative maintenance will pay big dividends in the form of reliable service of the pump.

1. Check power end oil level daily by means of the dipstick in the rear cover. Do not attempt to check the
oil level with the pump running. Inspect the oil for dirt or contamination and change if necessary. An
increase in oil level indicates fluid end leakage into power end. Change oil immediately and check
intermediate rod wipers and surface smoothness of the rod. Check for plunger packing leakage.

2. Lubricate the plunger packing frequently. Packing life can be greatly increased by greasing every four (4)
hours with a small amount of grease. Grease is not recommended for pressures exceeding 1200 psi. Use
an alternate packing lubricator to drip the proper oil for lubrication.

3. Check the Lubricator for proper oil level and operation. Refer to manufacturer specifications.

4. Check plunger packing for excessive leakage. Replace packing as necessary.

5. Drain and refill crankcase on power end as needed and at least every six (6) months maximum. Check
for debris in oil.

6. Clean crankcase breather monthly with a non‐explosive solvent.

7. Check all nuts and screws for proper torque. Inspect gaskets for leaks; tighten or replace as needed

8. Periodically clean the pump exterior. A clean pump is easier to maintain and it is easier to find and
locate potential maintenance issues.


LUBRICATION

1 GENERAL

NATIONAL OILWELL VARCO 415Q/300Q plunger pumps are "splash" lubricated. The main bearings and
crankshaft bearings are fed by splash by the operation of the pump. Crossheads and crosshead pin bushings
are fed through holes in the crossheads and crosshead reservoir. Intermediate rods are lubricated from the
splash they receive from the crosshead.

2 A. OIL

Use "extreme pressure" gear oil. The chart below shows the recommended grades for various temperatures
surrounding the pump. Use of any other oil or viscosity except those listed is strongly not recommended.

U.S. UNITS OF MEASURE
Temperature AGMA Industrial EP Gear Oil
+50°F to +155°F AGMA No. 6 EP or ASTM/ISO Grade No. 320 (viscosity 1335 to 1632 SSU 100°F)
+20°F to +100°F AGMA No. 5 EP or ASTM/ISO Grade No. 220 (viscosity 918 to 1122 SSU 100°F)
‐20°F to + 60°F AGMA No. 2 EP or ASTM/ISO Grade No. 68 (viscosity 284 to 347 SSU 100°F)

Crankcase Capacity ‐ Quarts: 300Q & 415Q – 12 gallons (48 quarts)

METRIC UNITS OF MEASURE
Temperature AGMA Industrial Gear Oil
+10°C to +68°C AGMA No. 6 EP or ASTM/ISO Grade No. 320 (Viscosity 228‐352 cSt at 37.8°C)
‐7°C to +38°C AGMA No. 5 EP or ASTM/ISO Grade No. 220 (Viscosity 198‐242 cSt at 37.8°C)
‐29°C to +16°C AGMA No. 2 EP or ASTM/ISO Grade No. 68 (Viscosity 61‐75 cSt at 37.8°C)

Crankcase Capacity ‐ Liters: 300Q & 415Q – 45.4 liters

Oil must pour freely at minimum operating temperature. Change oil at least every six (6) months or as
frequently as operating conditions require to maintain a clean, sludge‐free oil of proper viscosity.


3. Gear Reducer: Use "extreme pressure" gear oil.

Gear Reducer capacity by Ratio
2.27 6.5 gal (24.6 l)
2.89 5 gal (18.9l)
3.25, 3.36, 3.69 4.5 gal (17.1l)
4.38, 4.84, 5.63 3.5 gal (13.3l)

OVERHAUL AND REPAIR
Check Points and Adjustments
1. The crankshaft main bearings are non-adjustable, double row tapered roller bearings, factory set for the
proper running clearance.
2. The connecting rod crank end shell bearings are zinc coated solid aluminum alloy precision ground with
the following tolerances:
Crankshaft Rod Journal Diameter: 5.000/4.999” (127.00/126.975mm)

Maximum Clearance: .020” (.508mm)
Minimum Clearance: .0064” (.163mm)
Crosshead Wrist Pin Outside Diameter: 3.0015/3.0010” (76.238/76.225 mm)

Maximum Clearance: .008” (.203mm)
Minimum Clearance: .002” (.051mm)
3. The minimum allowable clearance between the crosshead and crosshead bore is .012” (.305mm). The
maximum allowable clearance, including wear, is .030” (.762mm)

DISASSEMBLY OF POWER END
I. GENERAL
When disassembling the power end it is not necessary to remove the fluid end and the plungers may be
disconnected from the intermediate rods and left in the stuffing boxes. It is necessary to drain the oil from the
power end. A large clean work area needs to be prepared before disassembly, parts needs to be kept in order
and grouped together so they can be reassembled in the same locations as a unit.
A. INTERMEDIATE RODS AND WIPER BOX
1. Drain oil from sump and dispose of properly. Remove the (Item 97) cap screws for the cradle
cover (Item 70) and the crosshead cover (Item 144).
70 & 144
97

2. Manually rotate the crankshaft to position the plunger completely into the stuffing box. Remove
the screws and washers (Items 747 & 32) and disconnect the plunger clamp (Item 700 & 701) and
separate the intermediate rod (Item 680) from the plunger (Item 745) and rotate the crankshaft
½ turn to retract the intermediate rod. If threaded plungers are installed, unscrew the (Item 745)
plunger from the intermediate rod (Item 680) and slip into stuffing box
747 & 32
700
745
680
701

3. Loosen the lock nuts (Item 223) on the wiper box (Item 134) and allow the hook bolts (Item
222) to rotate so they will pass through the bore in the power frame . Unscrew the
intermediate rod (item 680) from the crosshead (Item 212) and slide intermediate rod (Item
680) and wiper box out of the cradle as an assembly. Repeat the process with all (5) five
cylinders.
134
680 222
223

4. Remove the oil level dipstick (Item 26) before removing the cap screws for the rear crankcase
cover (item 48) and top crankcase cover (Item 145) to allow easier access to the connecting rod
bolts and bearing caps.
145
48
26
Remove oil trough (Item 401), cap screws (Item 36) and washers (Item 31) from inside top of crankcase.
31 & 45
401

5. Remove connecting rod bolts (Item 203) and remove bearing rod cap. NOTE: Keep the shell
bearings (Item 200) for the connecting rods with their respective mating parts. Push the
connecting rod and crosshead (item 212) into the bore of the power frame, or all the way
forward, to separate from the crankshaft (Item 105). Repeat process with all (5) five Connecting
Rods.
200
Connecting
Rod Cap
105
203

DISASSEMBLY AND REMOVAL OF GEAR REDUCER
1. If the crankshaft is not being removed, the crosshead and attached connecting rod can be removed
through the cradle by sliding them back through the oil chest. Be sure to keep the rod end shell
bearings (Item 200) and bearing caps together with their mating parts as they are fitted to one
another.
Connecting
Rod and
Gear Reducer
Crosshead
(optional)
Inspection
Cover
354
27
2. For connecting rod disassembly skip to page 27.
3. The crankshaft can only be removed from the left hand side of pump. If a gear reducer is installed it
will need to be removed to access the crankshaft. If no gear reducer is installed, skip to Step 12.
Remove inspection cover from gear reducer before removing gear reducer housing cover. Cut away
the slinger ring (Item 27) from pinion shaft. NOTE: Wrap a sling around the pinion gear shaft (Item
354) thru the inspection cover opening and support it with an overhead crane. The pinion gear
shaft and bearing (Item 356) can fall out of the housing when removing the cover causing injury
and damage to parts.

4. Drain oil from gear box and dispose of properly. Remove cap screws (Item 362) and gear housing
cover (Item 350) from housing. Remove the pinion gear shaft (Item 354) and outer bearing (Item
356). NOTE: Take care when removing pinion gear shaft that inner bearing does not fall out of
housing.
354
356
350
362

5. Remove the pinion gear shaft (Item 354) taking care the inner pinion shaft bearing (Item 356) does
not fall out. Using a large gear puller, dismount the gear (Item 375) from the crankshaft (Item 105).
356
354
105
375

6. Remove mounting screws (item ???) and gear reducer housing (Item 350) from power frame Take
care when separating the components, the housing is aligned with tapered dowel pins.
???
350

REMOVAL OF CRANKSHAFT
1. Cut away slinger ring (Item 25) and safety wire on hex bolts (Item 36). Remove right hand bearing
retainer (Item 23), gasket (Item 19) and hex bolt from power frame. Slinger ring will be replaced at
reassembly.
23 & 19
36
25

2. Cut away slinger ring (Item 25, on pumps without optional gear reducer) and safety wire on hex
bolts (Item 36). Remove caged bearing retainer (Item 24), gasket (Item 23) and hex bolts (Item 36)
from bearing cage (Item 141). Slinger ring will be replaced on reassembly.
25
141
24 & 19
36

3. Remove the (8) eight main bearing retaining rings (Items 509 & 510) from the center section of the
crankcase. These rings keep the crankshaft main bearings (Item 125) in location. There are (2) two
inner rings and (2) two outer rings for each bearing.
125
Power Frame
Transparent
for clarity 509
510

4. Remove the cap screws (Item 36) mounting the bearing cage (Item 141) to the left side of the power
frame.
141
36

5. Carefully and while supporting the crankshaft (Item 105), gently slide it out the left hand side of the
power frame. Care must be taken to keep from damaging the main bearing races and the bores of
the power end. The main bearing outer races will remain installed in the power frame while the
inner main bearing races will remain mounted to the crankshaft as will the outer tapered roller
bearing assemblies.
Crankshaft
Assembly
6. The crankshaft main bearing races must be inspected while on the crankshaft and should not be
removed unless necessary. If the tapered roller bearings are to be replaced, proper removal tools
are required.

DISASSEMBLY OF CRANKSHAFT
1. To disassemble the outer tapered roller bearings (Item 135), first bend the tang up in the lock
washer (Item 117) that is keeping the locking nut (Item 118) from rotating and unscrew the nut from
the crankshaft (Item 105). Once the locking nut and washer are removed a bearing puller is used to
remove the right side outer tapered bearing. On the left side a bearing puller is used to remove the
bearing cage (Item 141) and tapered bearing as a unit. The bearing can then be pressed out of the
bearing cage.
135
117
118
105
135
141
105
NOTE: The double row tapered roller bearings are not serviceable. They must be kept together as a
matched set if they are to be reinstalled. They are precision matched to the center spacer and must
be reassembled exactly as they were removed from the crankshaft

DISASSEMBLING THE WIPER BOX
1. The wiper box (Item 134) can be disassembled as shown in the image below. Replace the wiper rings
(Item 219), the gasket (Item 217) and the sealing washers (Item 301) to rebuild. Inspect the remaining
components for damage or excess wear and replace as needed,
134
260
222
217
219
4 places
301
223

DISASSEMBLING THE CONNECTING ROD
1. Complete disassembly of the connecting rod must be done in a particular order to keep from damaging
components. First, to separate the crosshead (Item 212) from the wrist pin (Item 213), remove the set
screw (Item 209) through the hole in the wrist pin.
212
213
209

2. Tap the wrist pin (Item 213) out of the crosshead (Item 212) gently to keep from damaging the edges.
Make sure the crosshead is secured to keep it from rolling off. Be sure to keep the crosshead and wrist
pin together with the rest of the connecting rod, they will need to be reassembled as a matched set.
212
213

3. Slide the crosshead (Item 212) from the end of the connecting rod and press out the wrist pin bushing
(Item 211). Take care not to damage the connecting rod in the process.
212
211

4. Exploded view of all parts of the connecting rod. These parts must be kept together as a matched set.
Do not mix parts with other connecting rods.

REMOVAL OF STUFFING BOX
1. Remove four (4) hex nuts (Item 620) from fluid end studs (Item 617).
620
617

2. Slip stuffing box assembly with plunger from studs and lift out of pump cradle.
Stuffing Box
Assembly
3. Repeat same steps for all five (5) stuffing boxes. Keep parts together for each stuffing box.

DISASSEMBLY OF STUFFING BOX
1. Loosen gland nut (Item 697 ) until plunger (Item 745) can be slipped out of packing.
697
745

2. Remove gland nut (Item 697) and pull gland (Item 707) and packing (Item 800) from stuffing box.
Remove spring follower (item 715) and spring (Item 719) to complete packing set removal.
719
715
800
707
697

3. Slip stuffing box (item 695) from retainer (Item 718). High pressure H Model stuffing boxes use a
retainer adapter (Item 748) to allow smaller stuffing boxes to fit retainer. Replace stuffing box seal (Item
696) upon reassembly.
696
695
748
optional
718

SEPARATING FLUID END FROM POWER FRAME
1. With stuffing boxes removed, the six (6) socket head cap screws (Item 269) holding the fluid end to the
power frame are accessible. Support the fluid end with a crane and remove the screws.
269
6 places

2. Slip the studs and fluid end from the power frame. The fluid end is now ready for tear down and
rebuild.

DISASSEMBLY OF FLUID END WITH SPHERICAL VALVES AND
SPHERICAL SEVERE DUTY VALVES (415Q-5L & 415Q-5M)
1. With fluid end resting in a stable position, remove hex nuts (Item 632) on valve covers (Item 625).
632
625

2. Gently pry valve cover (Item 625) loose and lift off. Locate and remove o-ring seal (Item 626) if it did not
stay with the valve cover.
625
626
3. Repeat process for all (5) five valve covers.

4. Both the spherical suction valve assembly and spherical discharge valve assembly (Item 911) are removed
from the top of the fluid end. It is necessary to remove the discharge valve assembly prior to removing
the suction valve assembly.
5. Remove the spring retainer for the discharge valve assembly by pressing downward on the spring retainer
with a large screw driver. Rotate 1/4th turn counter clockwise to unlock the spring retainer. Remove the
spring retainer, valve springs wave spring and valve body (with the retriever tool (Item 888).
152
SCREWDRIVER 153 & 155
90
156
888

6. Remove discharge valve seat by placing the puller head (Item 895) through the seat opening and engaging
the lugs to the underside of the valve seat. Pull seat loose using the puller tool (Item 890) and remove
from fluid end. Repeat Process for discharge valve assembly. See drawing 1716908 for the puller tool
assembly.
890
150
REMOVED
150
895
7. Repeat the process for each valve set until all five discharge valve and suction valve sets are removed. It
is very important to keep each valve with its seat as they are worn and mated to each other.

DISASSEMBLY OF FLUID END WITH CAGE TYPE VALVES
(415Q-5H)
1. With fluid end resting in a stable position, remove threaded cylinder cover (Item 625) and cage
loading hex bolt (Item 634).
634
625

2. Remove discharge valve retainer (Item 165) with hook end of valve retriever tool (Item 888).
3. Remove cover seal (Item 626) from top of upper valve cage with hook end of valve retriever tool
(Item 888).
888
160
626

4. Before removing discharge valve spring, observe amount of pre-load of spring at rest. Spring should
extend 1/8” to 3/16” above the top of the valve cage. If spring does not extend above the valve cage
it has become fatigued and will need to be replaced at rebuild. Remove valve spring with hook end
of valve retriever tool (Item 888).
888
153
159

5. Remove upper valve cage with valve installation tool (Item 159). WARNING: Take care not to pinch
hand or fingers between hammer and end stop when using valve installation tool.
WARNING: PINCH
POINT HAZARD
Keep hands and
fingers clear when
using
159
???

6. Remove discharge valve (Item 90) with magnet end of valve retriever tool (Item 888).
90
888
90

7. Insert valve seat Installation tool (Item 892) into discharge valve seat and rock back and forth to
break seal. Remove valve seat with hook end of valve retriever tool (Item 888). WARNING: Do not
damage thread on fluid end while prying out valve seats, place a rag over the edge of the valve
bore opening to avoid damage.
892 90
REMOVED
WARNING:
Do not damage
threads
90
8. Remove lower valve components in the same manner at Steps 3 thru 7. Remove bottom valve with hook end
of valve retriever tool (Item 888).
9. Repeat these steps on all bores to complete disassembly of valve components.
ASSEMBLING THE POWER END COMPONENTS
! ATTENTION !
Many components in the Power End are large, heavy and difficult to handle. Care must be taken to avoid
injury. Always use a hoist or crane and slings appropriate for the job.
CONNECTING ROD ASSEMBLY

1. Clear an area to work that is clean and free of debris. Most parts of the connecting rod are a precision fit
and need to be clean and free of dirt and debris to assemble correctly. The connecting rod cap and rod
are a matched set and marked as such. Make sure the cap and rod are the mates from the factory.
Locate the wrist pin bushing (Item 211) and find the marking on the edge for orientation and press into
the connecting rod end (Item 51). NOTE: FAILURE TO ALIGN HOLES CORRECTLY BETWEEN CONNECTING
ROD AND WRIST PIN BUSHING WILL QUICKLY CAUSE CONNECTING ROD FAILURE DUE TO LACK OF
LUBRICATION
TOP OF
CONNECTING
ROD
NOTE: HOLES MUST
ALIGN WHEN BUSHING IS
INSTALLED
51
NOTE: ORIENTATION OF
TOP OF BUSHING TO TOP
OF CONNECTING ROD
NOTE: THIS SIDE OF

BUSHING TOWARDS THE
ROD CAP END
211
CONNECTING ROD WITH DRIP LUBRICATION SHOWN

2. Install the set screw (Item 209) into the wrist pin (Item 213) from the inside with medium thread locking
compound. Thread in the set screw fully but not extending outside the wrist pin.
213
209

3. Slide wrist pin (Item 213) through the crosshead (Item 212) and wrist pin bushing (Item 211) until evenly
located in bore of crosshead. Tighten set screw to lock into place. Crosshead should pivot freely.
WARNING: ASSURE CORRECT ORIENTATION OF CONNECTING ROD AND CROSSHEAD OIL HOLE WHEN
ASSEMBLING. ASSEMBLING THE CROSSHEAD UPSIDE DOWN TO THE CONNECTING ROD WILL RESULT
IN WRIST PIN BUSHING FAILURE DUE TO LACK OF LUBRICATION.
TOP OF 212
TOP OF
212 CONNECTING
ROD
213

WIPER BOX ASSEMBLY
1. Install the wiper seals (Item 219) in the wiper box housing (Item 134) with a rubber mallet or dead blow
hammer in the orientation noted in the image below. Install grease lube fitting (Item 260) into top hole
of housing.
219
4 places
134
260

2. Install hook bolts (Item 222), sealing washers (Item 301) and lock nuts (Item 223) loosely through wiper
box housing (Item 134) with nuts opposite the gasket surface as shown in the image below. Install two
roll pins (item 693) into wiper box housing. Do not tighten until the wiper box assembly is ready to be
installed in the power frame. Stick the gasket (Item 217) to the wiper box housing with grease.
222
223
217
693
134
301

CRANKSHAFT ASSEMBLY
1. Clear an area to work that is clean and free of debris. All parts of the Crankshaft Assembly are precision
fit and have easily damaged surface finishes, they must be kept clean and free of dirt and debris to
assemble correctly. The Crankshaft is very large and very heavy and must be secured to keep it from
rolling or injury may occur.
WARNING: DAMAGE TO THE BEARING JOURNAL SURFACES WILL DRASTICALLY REDUCE SERVICE
LIFE FOR THE CRANKSHAFT ASSEMBLY, CARE MUST BE TAKEN.
Install the inner most set of Bearing Retaining Rings (Item 509) on the Crankshaft (Item 105) as shown
in the image below.
105
509

2. Remove the inner bearing race from the main bearings (Item 125) and heat evenly to prepare for press
fit to crankshaft (Item 105). Induction heating for the bearing races is recommended to apply even
heat and prevent warping or cracking the races. The outer main bearing assembly needs to be mated
back with its factory inner race at final assembly.
125
Outer Race
125
Inner Race

3. Slip heated inner bearing race onto crankshaft and gently tap up to bearing retaining ring (Item 509).
Do not damage the bearing race or the mating surfaces on the crankshaft during installation.
125
Inner Race
Installed
125
Inner Race
heated

4. Install the final pair inner main bearing retaining rings (Item 509).
509
509

5. Separate the outer dual roller bearings (Item 135) into four (4) parts; the two (2) tapered inner cone
races, the center spacer and the outer cup race. The two (2) tapered inner cone races must be heated
to press fit them onto the crankshaft in the same manner as the inner main bearing races. Induction
heating for the bearing races is recommended to apply even heat and prevent warping or cracking the
races.
Inner Cone
Bearing Race
Outer Cup
Bearing Race
Spacer
Inner Cone
Bearing Race

6. Slip heated inner bearing races onto accessory side of crankshaft (Item 105) and reassemble bearing
as shown in image below. Do not damage the bearing race or the mating surfaces on the crankshaft
during installation. Do not install bearing on drive side of crankshaft yet.
135 Installed
105
Accessory End

7. Install locking washer (Item 117) and bearing retainer nut (Item 118) on crankshaft (Item 105) and snug
against inner bearing race finger tight. Use anti-seize compound on the threads on the locking nut and
crankshaft
Anti-seize 117
compound
118
105
accessory
side
COMPLETED ACCESSORY SIDE BEARING INSTALLATION

8. Separate the remaining dual tapered roller bearing for the drive side of the crankshaft same as Step 5.
The inner cup races need to be heated to press fit them to the crankshaft (Item 105) and the outer
bearing cup (Item 135) needs to be frozen to press fit the bearing cage (Item 141). Press fit the outer
bearing cup race to the bearing cage first until it bottoms against the lip of the bearing cage.
141
Install bearing
race until it
bottoms out
135 Outer
Tapered Cup
Bearing Race

9. Install dual roller tapered bearing (Item 135) and bearing cage (Item 141) in order as shown in image
below. Do not damage the bearing race or the mating surfaces on the crankshaft during installation.
135 Inner
Bearing Cone
Race 2 places
105 drive
end
141 with 135

Outer Bearing
Cup installed
135
Spacer

10. Install locking washer (Item 117) and bearing retainer nut (Item 118) on crankshaft (Item 105) and
snug against inner bearing race finger tight in the same way as the accessory side. Use anti-seize
compound on the threads on the locking nut and crankshaft.
117
Apply anti-
seize
compound to
105 threads
141 installed
118 with
anti-seize
compound
on threads
COMPLETED DRIVE SIDE BEARING INSTALLATION

11. Crankshaft assembled ready for installation into Power Frame.
INSTALLATION OF MAIN BEARINGS

1. Freeze two (2) outer main roller bearing races (Item 125) to prepare to press fit them into the power
frame.
125

2. Install the main bearing outer snap rings (Item 510) into the inner most set of grooves in the power
frame (Item 1) as shown in the image below. Rotate snap rings so that the gap in the ring is
positioned at the bottom of the crankshaft bore and on each side of the anti-rotation pin (Item 689)
located in the bottom of the groove.
510
689
Anti-Rotation
Pin in groove

3. Slip cold main bearing outer races (Item 125) into power frame bearing supports and press up to main
bearing snap ring (Item 510). Install final main bearing snap rings on outside of main bearings. Main
bearing outer races are now installed with a snap ring on each side.
510 4 places
125 2 places

INSTALLATION OF CONNECTING RODS AND CROSSHEADS
1. Slide the assembled crosshead and connecting rod end into the crosshead bore through the power frame
cradle and slide it back until the connecting rod is the end of the crosshead bore. Coat the crosshead with
oil before installation.
NOTE: ORIENTATION OF CONNECTING ROD AND CROSSHEAD ASSEMBLY. OPEN END OF CONNECTING ROD
IS AIMED DOWN AND THE LUBE HOLE ON THE CROSSHEAD IS AIMED UP.
Lube hole in
crosshead
oriented up

INSTALLATION OF CRANKSHAFT
1. The assembled crankshaft is now ready to be installed into the prepared power frame. Coat all
bearing surfaces with oil. Slip the bearing cage gasket (Item 18) over the crankshaft assembly into
position on the bearing cage.
WARNING: EXTREME CARE MUST BE TAKEN WHEN INSERTING THE CRANKSHAFT INTO THE POWER
FRAME TO NOT DAMAGE THE BEARINGS. TAKE TIME TO MAKE SURE IT IS ALIGNED CORRECTLY OR
DAMAGE MAY OCCUR.
Assembled
Crankshaft
18

2. Install eight (8) drilled head hex head cap screws (Item 36) in bearing cage (Item 141). Using safety
wire, wire together the cap screws in pairs to prevent them from breaking loose.
141
36
8 places
Safety wire screws in

pairs through heads

COMPLETION OF CONNECTING ROD INSTALLATION
1. Rotate the crankshaft until the first throw is closest to the rear of the power frame. Install the shell
bearing (Item 200) halves onto the crankshaft (Item 105) as shown in the image below. Pull the
connecting rod up to the shell bearing and rotate the bearing until the dowel pin engages. The shell
bearing will snap into place locking it to the connecting rod. The shell bearing split should be vertical
and not aligned with the split in the connecting rod. If not as shown below, it is misaligned and must
be corrected.
WARNING: IMPROPER INSTALLATION OF SHELL BEARING WILL CAUSE IMMEDIATE DAMAGE TO
THE CRANKSHAFT AND BEARING SURFACES AND QUICKLY CAUSE CONNECTING ROD FAILURE
UPON STARTUP. TAKE CARE TO FOLLOW INSTRUCTIONS AND DIAGRAMS CLOSELY.
Assembled 105
Connecting Rod and
Crosshead
Dowel Pin
200
Split in vertical
position
CRITICAL ASSEMBLY INSTRUCTION FOR CORRECT INSTALLATION

POWER FRAME REMOVED FROM ILLUSTRATION FOR CLARITY

2. Repeat process with all five (5) connecting rods. Torque connecting rod bolts (Item 203) to 250 lbs-ft. Using
safety wire tie connecting rod bolts to one another.
203
2 places

COMPLETION OF CRANKSHAFT INSTALLTION
1. Using a block of wood positioned over the end of the crankshaft, strike each end of the crankshaft with a
sledgehammer two times to fully seat the outer tapered roller bearing races. WARNING: DO NOT STRIKE THE
CRANKSHAFT DIRECTLY WITH A HAMMER! Using a strap wrench, rotate the crankshaft and tighten the lock
nut on each end of the crankshaft. Align slot in locking nut (Item 118) with one of the tangs on the locking
washer (Item 117) and bend the tang down flat into the slot. The crankshaft is now completely installed and
located correctly in the power end.
117
Tighten and align with

117, bend tang down into
groove
118

2. Install the bearing retainer (Item 24) on drive side with gasket (Item 18) and bearing retainer (Item 23) with
gasket (Item 20) on the accessory side. Secure with drilled head hex head cap screw (Item 36). Using safety
wire tie pairs of screws to each other. Slip new slinger ring (Item 25) onto crankshaft and tap down to the
bearing retainer with a soft faced mallet. NOTE: If pump has gear reducer installed, do not install slinger ring
(Item 25) on drive side.
36
18
24
25 DRIVE SIDE
23
20
36
ACCESSORY SIDE 25

WIPER BOX INSTALLTION
1. Coat intermediate rod (Item 680) with grease and slip through the assembled wiper box. Position
wiper box assembly with gasket (item 217) in power frame cradle and hand thread the
intermediate rod into the crosshead. Push the wiper box assembly up to the power frame, rotate
the hook bolts (Item 222) so they pass through the bore and rotate so they hook the power frame
and contact the stop pins on the wiper box housing, then tighten the lock nuts (Item 223). Make
sure the wiper box assembly is oriented with the lube fitting (Item 260) upwards. Repeat process
for each of the five (5) wiper box assemblies. Torque intermediate rod to crosshead 480 ft-lbs (dry)
or 385 ft-lbs (lubricated).
217
134
680
Orient with
260 on top

FINAL POWER FRAME ASSEMBLY
1. Install pipe plugs (Items 370) as shown in image below and rear cover (Item 48) with gasket (Item
143) and oil level dipstick (Item 26) before filling crankcase with oil. Install oil troughs (Item 401)
with screws and washers (Items 31 & 45). After adding oil, mount crosshead cover with gasket
(Items 144 & 16) and breather (Item 14) on top of power frame. Install crankcase cover and gasket
(Item 144 & 39). Install all covers with hex cap screws (Item 97). Install crankcase sump drain plug
(Item 399). Power end is now fully assembled and ready for stuffing Box and Fluid End installation.
31 & 45
401
14
144 with 16
97
26 places
144 with 39
48 with 143
370 & 26
2 places 399

FLUID END ASSEMBLY – TAPERED VALVE SEATS
1. Clean the fluid end bores completely and wipe down the suction valve seat. The tapered seat and the
tapered bore in the fluid end must be clean and free of all debris for valve seat to be installed correctly.
WARNING: NEVER use grease or oil on tapered valve seats, valve seats are to be installed clean and
dry. Slip the suction valve seat into the tapered bore in the fluid end and using a brass bar and hammer
tap the valve seat into place. Repeat this process for all five (5) valve seats. The seat will be raised
slightly when installed and will be completely engaged when fluid end is pressurized at startup. Check
after installation that the seat is tight.
VALVE SEAT
5 PLACES
CORRECTLY
INSTALLED
VALVE SEAT

2. Assemble the remaining parts for the suction valve on top of the suction valve seat. Position the wave
spring on top of the valve seat, below the tabs on the seat. Then position the suction valve body on top
of the valve seat. Positon the valve spring on top of the suction valve body. Then slip the valve spring
retainer over the valve spring, push it down to compress the spring and rotate clockwise to lock it into
positon with a large screwdriver.
152
155
156
157

CORRECTLY INSTALLED COMPLETE SUCTION VALVE

3. Wipe down the discharge valve seat. The tapered seat and the tapered bore in the fluid end must be
clean and free of all debris for valve seat to be installed correctly. WARNING: NEVER use grease or oil
on tapered valve seats, valve seats are to be installed clean and dry. Slip the discharge valve seat into
the tapered bore in the fluid end and using a brass bar and hammer tap the valve seat into place.
Repeat this process for all five (5) valve seats. The seat will be raised slightly when installed and will be
completely engaged when fluid end is pressurized at startup. Check after installation that the seat is
tight.
VALVE SEAT
5 PLACES
CORRECTLY INSTALLED
DISCHARGE VALVE
SEAT

4. Assemble the remaining parts for the discharge valve on top of the discharge valve Seat. Position the
wave ring spring on top of the valve seat, and below the tabs on the valve seat. Then position the valve
body on top of the valve seat. Positon the inner valve spring on top of the suction valve body, then slip
the outer valve spring over the inner valve spring. Next slip the valve spring retainer over the valve
springs, push it down to compress the spring and rotate clockwise to lock it into positon with a large
screw driver.
152
153
155
157
156

CORRECTLY INSTALLED COMPLETE DISCHARGE VALVE

5. If the studs have been removed, insert four (4) studs (Item 631) per cylinder on the top of the Fluid End with
medium thread locking compound.
6. The valve cover studs (Item 631) should extend above the top deck of the fluid end by the amount listed below to
correctly allow for mounting the cylinder covers.
415Q-5L - 2 1/4”
415Q-5M – 3 1/2”
631
20 places

7. Coat the valve cover o-ring (Item 626) with grease and slip it over the round section of the valve cover (Item 625).
Slip the valve cover over the studs and screw the four (4) hex nuts (Item 632) onto each stud. Apply an anti-seize
compound with a K-factor of 0.14-0.16 to the threads of the hex nuts.
8. For 415Q-5M: Torque each hex nut to 670 lbs-ft dry or 500 ft-lbs lubricated (K-Factor = .15).
For 415Q-5L: Torque each hex nut to 190 lbs-ft dry or 250 ft-lbs lubricated (K-Factor = .15).
9. Repeat process for all five (5) bores.
632
625
626

10. Install the twenty (20) fluid end studs (Item 617) into the fluid end using a medium strength thread locker. The
studs should be 5 ½” above the mounting face when installed.
617

11. The M or L fluid end is now assembled and ready to mate up to the power end assembly.

FLUID END ASSEMBLY – CAGED VALVES, H FLUID END
1. The caged style valves, spherical and spherical severe duty, are for the H model fluid end only. Clean
the fluid end bores completely and wipe down the valve subassembly components. The valve
components and bore in the fluid end must be clean and free of all debris for valves to be installed
correctly. The diagram below shows the correct order for assembling the caged valve components.
NOTE: Spherical severe duty valve and seat are available as individual components, the spherical
severe duty valve and seat are available as a matched set.
160
626
153
159
90
626
153
159
90
626

2. Insert the first of three (3) seals (Item 626) into the bore of the fluid end and push it to the bottom.
Slip the first of two (2) valve seats into the bore on top of the seal. Push seat down until it goes
through seal and rests on the fluid end. A small amount of grease on the seal will help with
assembly. NOTE: Spherical severe duty valve shown.
90
626

3. Insert the first of two (2) valve bodies into the bore on top of valve seat. Slip valve cage down around
valve body against valve seat. NOTE: Severe duty valve assembly has an integrated urethane valve
insert. Spherical valve assembly does not use the urethane Insert. NOTE: Spherical severe duty valve
and seat are available as individual components, the spherical severe duty valve and seat are
available as a matched set. Spherical severe duty valve shown.
159
90

4. Slip the first of two (2) valve springs to the top of the valve body. Insert the second of three (3) seals
(Item 626) and push down to the top of the suction valve cage. A small amount of grease on the seal
will help with assembly.
626
153
CORRECTLY INSTALLED CAGED SUCTION VALVE

5. Slip the second of two (2) valve seats into the bore on top of the seal (Item 626) and valve cage. Slip
the second of two (2) valve bodies with urethane on to the top of the valve seat.
90
90
626

6. Insert the second of two (2) valve cages and push down to the top of the discharge valve seat. Slip
the second of two (2) valve springs to the top of the valve body.
153
159
CORRECTLY INSTALLED CAGED DISCHARGE VALVE

7. Insert valve cage retainer (Item 160) and seal (Item 626) on top of valve cage. Apply a small amount of grease
to the seal to aid in assembly.
160
626

8. Screw valve cover (Item 625) into fluid end.
625

9. Screw cage loading screw (Item 663) into valve cover and torque 900 ft-lbs dry or 735 ft-lbs lubricated ( K-
factor = .15).
663
10. Repeat these steps for all five (5) valve bores.

11. Install the twenty (20) fluid end studs (Item 617) with medium strength thread locker into the fluid end. The
studs should extend outside the fluid end by approximately 5 ½”.
617
12. The H Fluid End is now assembled and ready to mate up to the power end assembly.

FLUID END ASSEMBLY – MATING TO POWER END
1. Position the fluid end assembly against the mount end of the power end assembly. Screw in the six (6)
socket head cap screws (Item 269).
269
6 places
2. The assembled unit is now ready to install the stuffing boxes.
269

STUFFING BOX ASSEMBLY – SPRING LOADED BRAIDED
PACKING
1. Insert the packing spring and the spring follower into the stuffing box (Item 695) as shown in the image
below. Make sure all parts are clean and free of dirt and debris that can inhibit assembly and proper
sealing. Refer to drawing 1716895 for an exploded view for reference.
695
719
715

2. After lubricating packing components, insert the braided packing and packing spacers into the stuffing
box and slide down to the top of the spring follower as shown. NOTE: Pay attention to order of the
parts.
800

3. Slide the adapter ring (item 748) and stuffing box retainer (Item 718) over the long end of the stuffing
box and push down until adapter ring (Item 748) bottoms out. Note: Not all stuffing boxes use an adapter
ring.
Item 695
with packing
installed
748
(OPTIONAL)
718

4. Slide the gland (Item 707) into bore of stuffing box and then screw adjusting nut (Item 697) onto
stuffing box. Do NOT tighten.
707
697

5. Using grease, place the stuffing box o-ring (Item 696) in the groove on the back of the stuffing box.
Insert the plunger (Item 745) into the stuffing box as shown. The stuffing box is now ready to be
installed in the power frame cradle. Complete these steps for all five (5) stuffing boxes.
745
Assembled
Stuffing Box
696

STUFFING BOX ASSEMBLY – NON-ADJUSTABLE LIP STYLE
PACKING
1. Slip the stuffing box retainer (Item 718) onto the stuffing box (Item 695).
695
718

2. After lubricating packing components, insert the packing washer (Item 704) and packing into the
stuffing box (Item 695) and push down to the bottom of the counterbore. WARNING: Order of the
packing rings critical to proper sealing of plunger. Refer to cross section below.
802
800
CRITICAL: NOTE ORIENTATION OF PACKING RINGS

3. Slip the second packing washer (Item 802) and gland (Item 707) into the stuffing box (Item 695).
695
802
707

4. Hand tighten the adjusting nut (Item 697) onto the stuffing box (Item 695). Do NOT overtighten.
697

5. Keep o-ring seal (Item 696) with assembled stuffing box, it will be installed into the fluid end (item 85)
when stuffing box is installed.
696

STUFFING BOX ASSEMBLIES FOR 1045 JFD &
850-N UNIVERSAL PACKING
5” NATIONAL L CLASS STUFFING BOX ASSEMBLY
5” NATIONAL M CLASS STUFFING BOX ASSEMBLY
5” NATIONAL H CLASS STUFFING BOX ASSEMBLY

STUFFING BOX ASSEMBLIES FOR KEVLAR PACKING
5” NATIONAL L CLASS STUFFING BOX ASSEMBLY
5” NATIONAL M CLASS STUFFING BOX ASSEMBLY
5” NATIONAL H CLASS STUFFING BOX ASSEMBLY

STUFFING BOX ASSEMBLY WITH ASSEMBLED POWER
FRAME
1. Coat the plunger (Item 745) with plunger lube and slip it into the packing for the stuffing box as shown
below. Note the optional tapped hole is always oriented to the top of the stuffing box retainer.
NOTE: Location of
tapped hole in
retainer is always up
745

2. Slip the Intermediate rod baffle (Item 681) onto each intermediate rod (Item 680) as shown. Push them
approximately ¾” onto the rod past the clamping area.
681
680

3. Lower the assembled stuffing box with plunger into the power frame cradle with fluid end mounted.
Slip up onto power frame studs (Item 617) and finger tighten power frame hex nuts (Item 620). Rotate
the crankshaft as needed during assembly to retract the intermediate rods (Item 680) back into the
power frame to make room as needed. Repeat for all five (5) stuffing boxes. NOTE: When inserting the
stuffing box, make sure the seal (Item 696) is in the o-ring groove in the back of the stuffing box, or if
the o-ring is loose, it is pushed into the counterbore on the fluid end. On L fluid ends it is critical to
align the stuffing box outer diameter with counterbore of fluid end.
620
20 places
617
20 places

620
20 places
INSTALLED STUFFING BOX AND PLUNGER
4. When all five (5) stuffing boxes are completely installed, torque power frame hex nuts (item 620) to 640
ft-lbs.

INSTALLATION OF PLUNGER CLAMP
1. Slip the lower plunger clamp half onto the bottom of the mated intermediate rod (Item 680) and plunger
(Item 745). WARNING: The Plunger has a flat side on its head and the Intermediate Rod has tapered
side on its head. Align clamp half correctly.
Set the upper plunger clamp half on top of the mated plunger and intermediate rod. Screw the clamp
halves together using the hex cap screws with lock washers. Tighten evenly. Torque plunger clamp (Item
913) bolts to 30 lb-ft (dry). NOTE: A gap will appear between the plunger clamp halves when installed
correctly. The gap should be even side to side.
747
746
32
746

CORRECTLY INSTALLED PLUNGER CLAMP. COMPLETE FOR ALL FIVE (5) PLUNGERS

MOUNTING GEAR REDUCER AND FINAL ASSEMBLY
1. Slide the pinion bearing (Item 356) into the gear reducer housing and attach bearing cover (Item 359)
with supplied shims (Item 361) and cap screws (Item 36). Slide the gear reducer housing (Item 345) onto
the power frame and mount with eight (8) cap screws (Item 367). Torque cap screws to 375 ft-lbs.
Secure the cap screws in pairs with safety wire. When using a gear reducer, no slinger ring (Item 25) is
used and a different bearing retainer (Item 24) is used. If no gear reducer is installed, then skip to
Step 4. Screw in the pipe elbow (Item 371) and tighten until oriented up and screw in breather cap (Item
14). Install housing oil drain plug (Item 399)
36
359 & 361
356
24
14 & 371
345
367 399

2. Slip pinion shaft (Item 354) into pinion bearing in housing and heat gear (Item 375) up to 350°F before
pressing onto crankshaft (Item 105) with key (Item 563). Take care to support the pinion shaft with a
strap thru the inspection hole.
SUPPORT PINION SHAFT THRU

INSPECTION HOLE IN HOUSING
354
563
375

3. When gear is pressed on completely and aligned on the center of the pinion gear (Item 354), slide
second pinion bearing (Item 356) onto pinion shaft (Item 354) and mount gear reducer cover and slide
over pinion shaft (Item 354). Use silicone sealant to seal cover to housing. Secure with sixteen (16) cap
screws (Item 362) and align with three (3) tapered dowel pins. (item 365). Install handhole cover (Item
574) with gasket (Item 578) to top of gear reducer housing with cap screws (Item 36). Install two (2)
pipe plugs (Item 7) in cover.
574, 578
& 36
356
362 & 365

354
APPLY SILICONE SEALANT TO

ENTIRE SURFACE OF HOUSING
COVER
ITEM 7 INSTALLED IN HOLES DRILLED IN
COVER TO CHECK OIL LEVEL IN GEAR
REDUCER, LOCATION DETERMINED BY GEAR
RATIO USED
25
563
360
36

4. Mount rear cover (Item 48) with gasket (Item 143) and crankcase cover (Item 145) with gasket (Item 39)
with eighteen (18) cap screws (Item 97).
145 & 39
97 typical
18 places
48 and 143

5. Mount crosshead cover (item 144) with gasket (Item 16) and cradle cover (item 70) with eight (8) cap
screws (Item 45).
144 & 16
97
8 places
Item 70
6. The pump is now completely assembled and ready to fill with oil before operation.

PLUNGER LUBRICATION SYSTEM SERVICE
1. The plunger lubrication system is a belt driven drip lube system that delivers oil to the plunger and in
turn lubricates the plunger packing. It is driven by the crankshaft and the oil is stored inside the
lubricator’s reservoir. Servicing the lubricator pump consists of adjusting the mounting plate until the v-
belt is tensioned properly and the stainless steel lubrication lines are un-clogged and un-damaged. Over
tightening the v-belt will cause premature failure of the lubricator bearings. Inadequate lubrication will
cause premature failure of the packing and damage to the plunger. Inspect the pulleys and v-belt for
excess wear and replace as needed. See drawing 1716902 for the list of components.
2. The plunger lubricator requires regular service to refill the oil reservoir. Use Rockdrill Oil only for the
lubrication system as it is designed for long plunger and packing service life. Oil viscosity is determined
by the operating temperatures for the pump, see list on following page:

ROCK DRILL OIL LISTINGS

P-55U PUMP OPERATING INSTRUCTIONS
Box Suction Pumps (Vacuum Feed)
1. Fill Reservoir with oil.

2. Loosen union nut on pump outlet.
3. Remove the vent screw and fill the sight glass with oil. Prime by manually pumping flushing unit until air
free oil is observed from the drip tube and oil level drops in the sight glass.
4. Replace vent screw and tighten union nut.
5. Maintain oil level in sight glass below the drip tube so drops can be observed.
Flow Rate Adjustment

1. Loosen locknut on pump outlet.
2. Turn flushing unit counter-clockwise to increase flow.
3. Turn flushing unit clockwise to decrease flow.
4. Tighten locknut when desired flow rate is achieved
Sight Glass
In a vacuum type sight feed, it is not uncommon for oil level in the sight glass to drop during operation. Absence
of a level indicates air is being taken in with the oil. Some oils, due to viscosity conditions, will release air faster
than others. When the quality of air becomes excessive, it can eventually air lock the pump.
For this reason it is recommended that an oil level in the sight glass be maintained.
When level drops, remove the vent screw and fill sight glass to top; replace vent screw and operate flushing
unit manually, observing that an oil in the sight glass is free from air. If air is not expelled, it may be necessary
to loosen union nut (on pump outlet) and expel air at this point. It is desirable to maintain level below the drip
tube so drops can be seen during operation.

Over Filling of Sight Glass
In a vacuum type sight feed, it is not uncommon to see a reverse action whereas sight glass fills with oil and the
drops cannot be observed. Overfilling is caused by oil absorbing air in the sight glass and normally does not
affect the operation of the pump. Remove the vent screw from sight glass and allow level to drop below drip
tube. Tighten vent screw and check to see that air free oil from drip tube can be observed in the sight glass. If
overfilling continues, it may be caused by plunger wear and oil slippage is being drawn back to sight glass. If
this is the problem, the feed setting in drops per stroke will then automatically be reduced by the amount of
slippage.
Reservoir Oil Level (Loss of Prime)

If reservoir runs low on oil (at a point below the suction inlet of the pump) it may be necessary to prime
individual pumps after filling, using procedure listed above.
Pump Displacement
Maximum output (per stroke):
1/4 Plunger = .018 Cubic Inches

3/8 Plunger = .038 Cubic Inches
The cubic volume for a pint of oil is 28.9 cubic inches and average drop size is .002 cubic inches.
TYPICAL PUMPING UNIT, ONE PER PLUNGER

PLUNGER PACKING ADJUSTMENT
1. Gland nut should be installed hand tight in preparation for packing adjustment at assembly. Complete
attachment of plunger to intermediate rod and install the plunger clamp.
2. Tighten adjustment nut as tight as possible with bar furnished with the pump. DO NOT USE A CHEATER!
For Non-Adjustable Lip Style Packing:

1. Start pump and operate under pressure; retighten gland adjustment nut. After pump has been running
for two (2) or three (3) hours under pressure, packing will be seated and the gland adjustment nut
should be tightened as much as possible with bar furnished with the pump. DO NOT USE A CHEATER!
This will remove any movement of the packing in the stuffing box.
2. The gland adjusting nuts should be checked and tightened for the first two (2) or three (3) days until
the packing is fully seated and the gland adjusting nuts cannot be tightened any further. DO NOT USE A
CHEATER!
For Spring Loaded Braided Packing

1. After assembly, tighten packing adjustment nut. Bushing should seat against the stuffing box face. Back
the nut off one-half turn using the supplied stop pin.
2. Fill the lubricator pump with rock drill oil for normal operation temperatures or steam cylinder oil for
high temperature operation. Fill out the lubricator lines by manually pumping the unit. Check its
operation.
3. Start pump at low speed and low pressure operation if possible, tighten stuffing box adjustment nut
and insert stop pin in hole. Watch operation for a short period of time. Oil if needed.
4. Set lubricator to twice normal rate. After 24 hours, resume normal operation. Check stuffing box for
excessively high temperatures and abnormal leakage.

STORAGE
If the pump is to be idle for more than one (1) week, it should be prepared for storage as follows:
1. Drain and clean crankcase thoroughly. Leave drain open and install 90⁰ elbow, pointed downward, to
permit air circulation and prevent condensation buildup.
2. Coat all bearings, finished surfaces and entire interior of crankcase with rust inhibiting oil.
3. Remove plungers and packing and coat with rust inhibiting oil.
4. Remove fluid end valves allowing cylinder to be thoroughly clean and drained.
5. Coat entire fluid end, valves and parts with rust inhibiting oil.
6. Thoroughly inspect and rotate crankshaft monthly. Re-coat with rust inhibiting oil as needed.
RE-START AFTER STORAGE

Any pump that has been in storage, either after field use or as shipped from the plant, will need a
thorough inspection to make sure it has not been damaged in any way and that all parts are in proper
place before start up.
1. Remove all covers from Power End and Fluid End; thoroughly clean and inspect all parts and finished
surfaces.
2. Check all bearings to make sure they are clean in good working order.
3. Make sure all packing, plungers and valves are installed correctly and in good condition.
4. Fill Power End to the proper level with clean oil of the proper viscosity. Make sure the oil is filled in the
Crosshead Reservoir and is worked into all bearings.
5. Fill Packing Lubricator and Lubricator Lines until full. Check by breaking connection at Stuffing Box and
running Lubricator Pump until fresh oil appears and then reconnect Lubricator line.

TROUBLESHOOTING

With over 120 locations worldwide, National Oilwell Varco is located near you. To find
the nearest Distribution Service Center, machinery center or repair facility, please give
us a call at our main office listed below.
Or you can access our website at the URL listed below, where you may search by
location or country.
http://www.nov.com/contactus.aspx
Sales/Technical Information: National Oilwell Varco is a leading © Copyright 2016 by National Oilwell, L.P. All Rights
Reserved. NATIONAL OILWELL, NATIONAL, and
USA: 1 918 447 4600 manufacturer of reciprocating plunger OILWELL are registered trademarks of NATIONAL
pumps, centrifugal pumps, and fluid end OILWELL, L.P. Houston, Texas, USA. All other
replacement parts. We also offer a trademarks used are registered to their respective
Internet: http://www.nov.com complete set of solutions to your fluid companies. The information and data in this
brochure, including but not limited to pictures,
transfer challenges. For more Information, photographs, charts, diagrams, drawings, lists,
contact National Oilwell Varco directly at written comments, and specifications, are accurate to
the Headquarters in Houston, Texas. All the best of our knowledge and belief, but are
intended for general information only. Applications
National Oilwell Varco products are suggested for the materials and other information are
available throughout the U.S. and around described only to help readers make their own
the world from service centers, authorized evaluations and decisions, and are neither
guarantees nor are they to be construed as express
distributors, and representatives. or implied warranties of suitability for these or other
applications. National Oilwell makes no warranty,
either express or implied, beyond that stipulated in
National Oilwell’s Standard Terms and Conditions of
Sale which are available upon request.
415Q MASTER FIND NUMBER ASSIGNMENT LIST 001-899
FIND PART NUMBER DESCRIPTION
1 171600141 POWER FRAME
7 6874008 PIPE PLUG
9 6874012 PIPE PLUG
14 7802020 BREATHER CAP
16 1716100 GASKET, CROSSHEAD COVER
18 1713008 GASKET, MAIN BEARING CAGE
19 1713010 GASKET, MAIN BEARING CAGE RETAINER
20 1713009 GASKET, MAIN BEARING RETAINER (DRIVE SIDE)
23 1713017 RETAINER, CRANKSHAFT
24 1713022 RETAINER, CAGE SIDE, CRANKSHAFT
25 7818106 SLINGER, CRANKSHAFT
26 2400054 DIP STICK, OIL LEVEL
27 1127523 SLINGER, GEAR REDUCER
31 7618018 WASHER, 1/2" FLAT
32 154-012087-405 WASHER, 1/2" SPRING LOCK
33 155-100200-286 WASHER, 1" FLAT
36 2400930 SCREW, 5/8"-11UNC X 1 3/4" LG, DRILLED HEAD
37 2405018 SCREW, DR HD HEX HD CAP 7/8"-9 x 4 1/2" LG - GEARBOX MOUNTING SCREWS
39 1716101 GASKET, CRANKCASE COVER
40 1713560 COVER, CRANKSHAFT EXTENSION
41 7619050 WASHER, 1/2" SPRING LOCK
42 7026299 SET SCREW, HEX SOCKET
44 100-034112-290 CAP SCREW, HEX HEAD, 3/4"-10UNC X 1 1/2" LG
45 100-012100-290 CAP SCREW, HX HD, 1/2"-13UNC X 1" LG
46 100-034100-290 CAP SCREW, HEX HEAD, 3/4"-10UNC X 1" LG
47 100-014012-286 CAP SCREW, HEX HEAD, 1/4"-20UNC X 1/2" LG
48 171601541 COVER, REAR
60 100-058112-286 CAP SCREW, HEX HEAD, 5/8"-11UNC X 1 1/2" LG
61 100-012114-286 CAP SCREW, HEX HEAD, 1/2"-13UNC x 1 1/4" LG
70 1716399 CRADLE COVER
75 171602341 POWER END ASSM 415Q-5 LH L/INTERMEDIATE RODS
80 17131782341 FLUID END STUDDED 415Q-5H DPSS
80 17162411441 FLUID END STUDDED 415Q-5L14CF CBRZ
80 17162412341 FLUID END STUDDED 415Q-5L23CF DPSS
80 17132182341 FLUID END STUDDED 415Q-5M DPSS
80 17132181441 FLUID END STUDDED 415Q-5M14CF CBRZ
80 17131781441 FLUID END STUDDED, 415Q-5H14AF CBRZ
85 17131791441S FLUID END ASSY 415Q-5H14AF CBRZ SPHERICAL VALVES
85 17131791441SD FLUID END ASSY 415Q-5H14AF CBRZ SEVERE DUTY SPHERICAL VALVES
85 17131792341SD FLUID END ASSY 415Q-5H14AF CBRZ SEVERE DUTY SPHERICAL VALVES
85 17131792341S FLUID END ASSY 415Q-5H23AF DPSS SPHERICAL VALVES
85 17162421441W FLUID END ASSY 415Q-5L14CF CBRZ SPHERICAL VALVES
85 17162422341W FLUID END ASSY 415Q-5L23CF DPSS SPHERICAL VALVES
85 17132172341 FLUID END ASSY 415Q-5M23CF DPSS SEVERE DUTY SPHERICAL VALVES
85 17132191441W FLUID END ASSY 415Q-5M23CF DPSS SEVERE DUTY SPHERICAL VALVES
85 17132192341W FLUID END ASSY 415Q-5M23CF DPSS SPHERICAL VALVES
90 179402025W VALVE ASSY, SUCTION, SPHERICAL 4" (415Q-5L)
90 179402025SD VALVE ASSY, SUCTION, SEVERE DUTY SPHERICAL 4" (415Q-5L)
90 171709025 VALVE ASSY, SPHERICAL 1.5" (415Q-5H)
90 179302025W VALVE ASSY, SPHERICAL 3" (415Q-5M)
90 179302025SD VALVE ASSY, SUCTION, SEVERE DUTY SPHERICAL 3" (415Q-5M)
91 179402225W VALVE ASSY, DISCHARGE, SPHERICAL 4" (415Q-5L)
91 179402225SD VALVE ASSY, DISCHARGE, SEVERE DUTY SPHERICAL 4" (415Q-5L)
91 179302225SD VALVE ASSY, DISCHARGE, SEVERE DUTY SPHERICAL 3" (415Q-5M)
91 171709025SD VALVE ASSY, SEVERE DUTY SPHERICAL 1.5" (415Q-5H)
91 179302225W VALVE ASSY, DISCHARGE, SPHERICAL 3" (415Q-5M)
97 100-012112-290 CAP SCREW, HEX HD, 1/2"-13UNC x 1 1/2" LG
100 180104143 PULLER ASSY (415Q-5L)
100 180104127 PULLER ASSY (415Q-5M)
105 X173412 CRANKSHAFT W/NUTS
105 X173412RD CRANKSHAFT, RIFLE DRILLED
109 2404019 KEY, CRANKSHAFT
117 7610050 WASHER, TIMKEN
118 6304048 LOCK NUT, TIMKEN
125 ZB10500 BEARING, CRANKSHAFT, INBOARD
134 1716009 WIPER RETAINER
135 ZT5506 BEARING, CRANKSHAFT, OUTBOARD
141 1713007 MAIN BEARING CAGE
143 1716102 GASKET, REAR COVER
144 1713013 PLATE, CROSSHEAD COVER
145 1713014 COVER, CRANKCASE
150 179402125 SEAT, SUCTION 4"
150 171709025SD VALVE SEAT, 415Q-5H
150 179302125 VALVE SEAT, SUCTION, 3" + 179302725 VALVE BODY (MATCHED SET)
151 179402325 SEAT, DICHARGE 4"
151 179302725 VALVE, DISCHARGE, 3" + 179302325 VALVE SEAT (MATCHED SET)
152 17930246W RETAINER, 3" VALVE
152 17940246W RETAINER, 4" VALVE
153 1793025 VALVE SPRING, OUTER, 3" VALVE
153 1794025 VALVE SPRING, OUTER, 4" VALVE
154 179402725SD VALVE, SPHERICAL 4"
155 1793026 VALVE SPRING, INNER 3"
155 1794026 VALVE SPRING, INNER 4"
156 9707082 WAVE RING, 3" VALVE
156 9707080 WAVE RING, 4" VALVE
157 171709125 VALVE SEAT, SPHERICAL + VALVE, SPHERICAL H (MATCHED SET)
158 179302725SD VALVE BODY, SD, 3", 415Q-5M
158 179402725SD VALVE BODY, SD, 4", 415Q-5L
158 171709225SD VALVE BODY, SD, 415Q-5H
159 17125854 CAGE, VALVE 415Q-5H
160 17134174 RETAINER, VALVE CAGE, 17-4SS
160 17134172 RETAINER, VALVE CAGE, BRZ 415Q-5H
161 1712486 VALVE SPRING, CAGE 415Q-5H
164 9707086 VALVE INSERT, 3" SD SPHERICAL
164 9707084 VALVE INSERT, 4" SEVERE DUTY
164 9707094 VALVE INSERT, SD SPHERICAL
200 1716104 BEARING HALF, CONNROD
203 21032044 CAP SCREW, DRILLED HEAD, CONROD
206 1711745 PIN, DOWEL, 3/8 DIA X 1"
209 H7028104 SCREW, HEX SOC CONE PT SET 1/4
211 1716030 BUSH,CROSS J165/275 for Field Repair
211 1716010 BUSH,CROSS/H PIN J165/275 Has to be HONED
212 1716005 CROSSHEAD
213 1716008 PIN, CROSSHEAD
217 1716017 GASKET, WIPER BOX
219 1713297 WIPER, OIL
222 1716031 BOLT, HO0K
223 6308080 NUT, LOCK
229 6510604 PIN,DOWEL STD HDN & GR,3/8X1/2 x 1
260 180-161020-220 LUBE FITTING (WIPER BOX)
269 105-012214-290 CAP SCREW, SKT HEAD
270 1717884 REDUCER,GEAR CPT 4.84 SPCL WID
279 G1716004 CONNROD ASSM, COMPLETE
299 1716122LSS LUBRICATOR ASSM, LHAND
300 1716122RSS LUBRICATOR ASSM, RHAND
301 7600032 WASHER, 1/2" SEALING
310 170-038001-220 PIPE PLUG
345 1713602 HOUSING COMPLETE, GEAR REDUCER
351 1711606 PLATE, NAME TAG G/R
352 1108210 GASKET, HANDHOLE COVER
353 1108110 COVER, HAND HOLE
354 1717881 PINION,HS 6.200 PD,4.84 WIDE
356 ZT3621 BEARING, SINGLE ROW TAPERED
358 1713605 CAP, PINION BRG OPEN
359 1713604 CAP, HS, PINION BRG, BLIND
360 1713621 RETAINER, G/R BRG J275
361 1713628 SHIM KIT, BEARING (GEAR REDUCER)
362 100-034234-290 CAP SCREW, HEX HD, 3/4"-10UNC X 2 3/4" LG
363 45805430 #10 TAPER PIN AND NUT
364 1713601 COVER,G/R MACHINED,300Q
365 6581072 PIN, TAPERED, GR TO PF
366 100-038034-290 CAP SCREW, HEX HEAD, 3/8"-16UNC X 3/4" LG
370 170-114004-353 PIPE PLUG
371 6829008 ELBOW, STD 1" M.I. STREET 90
375 1717882 GEAR,30.0 PD WIDE F/
377 1713625 SHIM, BRG RETAINER .005
399 7815059 PLUG, MAGNETIC DRAIN 1-1/4 405
401 1713016P OIL TROUGH, CRANKSHAFT
509 1716019 RING, SNAP, MAIN BEARING
510 1716018 RING, SNAP,
520 1790080 BUMPER, VALVE PULLER
521 1790082 WRENCH VALVE SPRING RETAINER
522 705509101 SCREW, FILLISTER HEAD, #10-24UNC
523 1790044 MAGNET
526 1790033 RETRIEVER
527 7817130 ROD, THREADED, 1"-8UNC
528 1790035 HANDLE, SEAT REMOVAL & INSTALL TOOL
530 1790038 HEAD, SEAT INSTALL AND REMOVAL TOOL
531 1710250 BAR, ONLY BUMPING
540 1716911 PLT,PUMP MTG,PLGR LUBE,5" PUMP
541 7811075 LUBRICATOR, 5 FEED LH
541 7811073 LUBRICATOR, 5 FEED
543 64226988 MALE ELBOW
544 104-038400-286 STUD, ALL THREAD
545 154-038068-286 WASHER, LOCK, ZINC PLTD (CFS)
546 155-038100-286 WASHER,PLAIN (CFS)
547 133-038016-286 NUT, ZINC PLTD (CFS)
548 100-012200-290 CAP SCREW x 4
549 1716912 GUARD,BELT,PLGR LUB, 5"PUMP
550 100-058100-290 CAP SCREW x 2
551 7200020 SHEAVE, 6.2 PD 1 A GRV W/ 5/8
552 7027208 SCREW, HEX SOCKET HD CUP PT SE
553 1713021 SHEAVE, 6 IN PD CRANKSHAFT (View)
554 4712530 V-BELT
555 1716914 GUARD,C'SHAFT,PLGR LUBE,5"PUMP
556 100-058612-290 CAP SCREW
557 330-002003-365 TUBING 1/4 OD STNLS STL 035 WA x 504
558 7802201 CLIP, ADEL
560 49011837 TEE
561 2402990 KEY, 7/8 X 7/8 X 4 PLAIN
562 133-138006-286 NUT, HEAVY HEX, 1 3/8"-6UNC
565 2404048 KEY, 1-1/4 X 1-1/4 X 5-1/2 PLA
617 104-138712-286 STUD, 1-3/8"-6 UNC X 7 1/2" LG
620 133-138006-286 NUT, HVY HEX, 1-3/8-6UNC
625 1712033 COVER, CYL TOP 415Q-5M
625 171207323 VALVE COVER, DSS (415Q-5L)
625 170948423 VALVE COVER, DSS 4A (415Q-5H)
625 171203323 VALVE COVER, DSS 4A (415Q-5M)
625 17094842 VALVE COVER, NAB (415Q-5H)
625 1712073 VALVE COVER, NAB (415Q-5L)
626 1712373 VALVE COVER SEAL (415Q-5H)
626 2410031429 VALVE COVER SEAL (415Q-5L)
626 2410031345 VALVE COVER SEAL (415Q-5M)
631 104-100334-286 STUD
631 104-112512-186 STUD
632 133-112006-286 NUT, HVY HEX, 1 1/2-6UNC
632 133-100008-286 NUT, HVY HEX, 1-8UNC
659 204-000063-214 GASKET (415Q-5L)
659 200-045002-405 RTJ GASKET, R45 (415Q-5M & 5H)
660 100-034200-290 CAPSCREW, HEX HD (415Q-5L)
660 100-034312-290 CAPSCREW, HEX HD (415Q-5M & 5H)
663 1713410 SCREW, HX HEAD, CAGE LOADING 415Q-5H
673 200-026002-405 R26 RING JOINT SEAL (415Q-5H)
673 200-035002-405 R35 RING JOINT SEAL (415Q-5M)
673 200-037002-405 R37 RING JOINT SEAL (415Q-5L)
674 100-100400-290 CAP SCREW, HEX HD (415Q-5H)
674 100-078312-290 CAP SCREW, HEX HD (415Q-5L)
674 100-118400-290 CAP SCREW, HEX HD (415Q-5M)
680 340-019 INTERMEDIATE ROD, CLMP
680 340-023 INTERMEDIATE ROD, THD
681 1717016 BAFFLE
685 AAB-119199-405 NAME PLATE
686 126-006516-405 DRIVE SCREW, #6 X 5/16" (PFS)
689 6578016 PIN, SPRING 1/8" (ANTI-ROTATION)
690 6572420 PIN, SPRING 3/8" (CROSSHEAD LUBE)
691 6572016 PIN, SPRING, 5/16"
692 6571216 PIN, SPRING 3/16"
693 6541612 PIN, USA TYPE "C" GROOVE 1/4
695 L342-908 STUFFING BOX, 1.88 - 2.00 PLGR (415Q-5H)
695 342-948 STUFFING BOX, 2.13 PLGR (415Q-5H)
695 342-915 STUFFING BOX, 2.25 - 2.50 PLGR (415Q-5H)
695 342-952 STUFFING BOX, 2.63 PLGR (415Q-5M)
695 342-924 STUFFING BOX, 2.75 - 3.00 PLGR (415Q-5M)
695 343-042 STUFFING BOX, 3.13 - 3.25 PLGR (415Q-5M)
695 343-012 STUFFING BOX, 3.38 - 3.50 PLGR (415Q-5L)
696 2410031342 PACKING, RECT. 3.60X4.006X.20 (415Q-5M & 5H)
696 2410031347 PACKING, RECT. 4.225X4.63X.20 (415Q-5L & 5M)
696 2410031334 PACKING, RECT. 2.60X 3.00 X.20 (415Q-5H)
696 08423022 STUFFING BOX GASKET (415Q-5L)
697 L342-913 NUT, ADJUSTING, 17-4, 1.50 - 2.13 PLUNGERS (415Q-5H)
697 342-916 NUT, ADJUSTING, 17-4, 2.25 - 2.63 PLUNGERS (415Q-5M & 5H)
697 342-928 NUT, ADJUSTING, 17-4, 2.63 - 3.00 PLUNGERS (415Q-5M)
697 342-927 NUT, ADJUSTING, 17-4, 3.13 - 3.50 PLUNGERS (415Q-5L)
697 343-013 NUT, ADJUSTING, 17-4, 3.38 - 4.50 PLUNGERS (415Q-5L)
697 343-091 NUT, ADJUSTING, DPSS, 1.50-2.13 PLUNGERS (415Q-5H)
698 1710270 BAR, STBX ADJUSTING NUT
699 1712326 BAR, STBX ADJUSTING NUT
707 L342-167 GLAND,OUTER 1.88 PKG (415Q-5H)
707 L342-168 GLAND,OUTER 2.00 PKG (415Q-5H)
707 342-121 GLAND,OUTER 2.12 PKG (415Q-5H)
707 342-005 GLAND,OUTER 2.25 PKG (415Q-5M)
707 342-125 GLAND,OUTER 3.13 PKG (415Q-5L & 5M)
707 343-044 GLAND,OUTER 3.25 PKG (415Q-5L & 5M)
707 343-023 GLAND,OUTER 3.38 PKG (415Q-5L)
712 342-930 PIN H LOCK STBX J100/165
712 342-914 PIN H LOCK STBX J30/60/100/165
715 342-002 SPRING FOLLOWER 2.50 X 3.25 BRS (415Q-5M)
715 342-014 SPRING FOLLOWER 2.75 x 3.75 H PKGN (415Q-5M)
715 342-356 SPRING FOLLOWER 2.88 H OUTR BRASS (415Q-5M)
715 342-015 SPRING FOLLOWER 3.00 X 3.75 H PKGN (415Q-5M)
715 342-357 SPRING FOLLOWER 3.13 X 4.13 KV (415Q-5L & 5M)
715 343-045 SPRING FOLLOWER 3.25 X 4.13 (415Q-5L & 5M)
715 343-039 SPRING FOLLOWER 3.38 X 4.25 (415Q-5L)
715 342-028 SPRING FOLLOWER 3.50 X 4.25 KV (415Q-5L)
715 342-360 SPRING FOLLOWER 4.00 H OUTR BRASS (415Q-5L)
715 343-036 SPRING FOLLOWER 4.13 X 5 (415Q-5L)
715 343-035 SPRING FOLLOWER 4.25 X 5 (415Q-5L)
715 343-034 SPRING FOLLOWER 4.38 X 5-1/4 (415Q-5L)
715 342-392 SPRING FOLLOWER 4.50 H BRS360 (415Q-5L)
715 342-353 SPRING FOLLOWER H 1.12 BRS360 (415Q-5H)
715 L342-367 SPRING FOLLOWER H 1.88 x 2.75 PKGN (415Q-5H)
715 L342-368 SPRING FOLLOWER H 2.00 x 2.75 PKGN (415Q-5H)
715 342-001/26 SPRING FOLLOWER H 2.25 x 3.25 PKGN (415Q-5M & 5H)
715 342-354 SPRING FOLLOWER H 2.38 BRS360 (415Q-5M)
715 342-355 SPRING FOLLOWER H 2.62 BRS360 (415Q-5M)
718 1713834 RETAINER, STUFFING BOX (415Q-5L & 5M)
718 1716034 RETAINER, STUFFING BOX (415Q-5M)
718 17133041 RETAINER, STUFFING BOX (415Q-5H)
719 L342-260 SPRING 1.88/2.00 PKG (415Q-5H)
719 342-000/26 SPRING 2.25/2.50 PKG (415Q-5M & 5H)
719 342-270 SPRING 2.63/2.88 PKG (415Q-5M)
719 342-008/26 SPRING 2.75/3.00 PKG (415Q-5M)
719 342-268 SPRING 3.13/3.38 PKG (415Q-5L & 5M)
719 342-007 SPRING 3.25/3.50 PKG (415Q-5L)
719 343-025 SPRING 3.63/3.75 PKG (415Q-5L)
719 342-269 SPRING 3.75/4.00 PKG (415Q-5L)
719 343-024 SPRING 4.13/4.25 PKG (415Q-5L)
719 342-272 SPRING 4.25/4.50 PKG (415Q-5L)
745 L340-147 PLUNGER 1.88 TC CP NT 5.00 STK
745 1716054 PLUNGER 2.00 CR CP NT 5.00 STK
745 1712039 PLUNGER 2.00 CR TD NT 5.00 STK
745 L340-148 PLUNGER 2.00 TC CP NT 5.00 STK
745 L340-188 PLUNGER 2.00 TC TD NT 5.00 STK
745 340-200 PLUNGER 2.13 TC CP NT 5.00 STK
745 340-197 PLUNGER 3.50 TC TD NT 5.00 STK
746 1716037 CLAMP CPT PLGR
747 100-012300-290 CAP SCREW, HEX HD, 1/2-13UNC X 3" LG (PLUNGER CLAMP)
748 L342-907 RETAINER ADAPTER, 2.50-2.75 SBX (415Q-5H)
748 342-958 RETAINER ADAPTER, H RING (415Q-5H)
748 342-933 RETAINER ADAPTER, H RING (415Q-5M & 5H)
800 6422322N858 PKG SET 0858 2.00X2.75X2.25X1.44 (415Q-5H)
800 171619941 PKG SET 1058-4 415Q-5 2.00 X 1 (415Q-5H)
800 6422343 PKG SET 850N 3.50 X 4.25 X 1 (838) (415Q-5L)
800 L342-767 PKG SET H 1.88 X 2.75 J PUMPS (415Q-5H)
800 342-768 PKG SET KEV/BRS 2.00X2.75X1.44 (415Q-5H)
800 342-751 PKG SET KEV/BRS 2.13X2.88X1.44 (415Q-5H)
800 342-003 PKG SET KEV/BRS 2.25X3.25X1.83 (415Q-5M & 5H)
800 342-752 PKG SET KEV/BRS 2.38X3.25X1.65 (415Q-5M)
800 342-755 PKG SET KEV/BRS 3.13X4.13X1.83 (415Q-5L)
800 342-843 PKG SET KEV/BRS 3.25X4.13X1.65 (415Q-5L & 5M)
800 343-027 PKG SET KEV/BRS 4.38X525X1.65 (415Q-5L)
800 L342-790 PKG SET KEV/BRS 4.50X5.25X1.44 (415Q-5L)
802 1712098 WASHER, STD 3.50 X 4-1/4 850N x 2 (838)
850 345-067 PK 1.88 TC TD KEVL 17-4 165T (415Q-5H)
850 345-031 PK 1.88 TC CP KEVL 17-4 165T (415Q-5H)
850 345-114 PK 2.00 TC CP KEVL 17-4 165T (415Q-5H)
850 347-125 PK 2.00 TC CP KEVL DPSS 415Q (415Q-5H)
850 342-109 PK 2.13 TC CP KEVL 17-4 165T (415Q-5H)
850 345-033 PK 2.25 TC CP KEVL 17-4 165T (415Q-5M & 5H)
850 345-110 PK 2.38 TC CP KEVL 17-4 165T (415Q-5M)
850 345-034 PK 2.50 TC CP KEVL 17-4 165T (415Q-5M)
850 345-111 PK 2.63 TC CP KEVL 17-4 165T (415Q-5M)
850 345-035 PK 2.75 TC CP KEVL 17-4 165T (415Q-5M)
850 345-333 PK 2.88 TC CP KEVL 17-4 165T (415Q-5M)
850 345-036 PK 3.00 TC CP KEVL 17-4 165T (415Q-5M)
850 345-332 PK 3.13 TC CP KEVL 17-4 415Q (415Q-5M)
850 345-351 PK 3.25 CR CL KEVL 17-4 415Q (415Q-5M)
850 345-331 PK 3.25 TC CL KEVL 17-4 250T (415Q-5M)
850 345-219 PK 3.38 TC CP KEVL 17-4 415Q (415Q-5L)
850 347-038 PK 3.50 CR CP KEVL 17-4 415Q (415Q-5L)
850 345-218 PK 3.50 TC CP KEVL 17-4 415Q (415Q-5L)
850 345-107 PK 3.50 TC TD KEVL 17-4 415Q (415Q-5L)
850 345-217 PK 3.63 TC CP KEVL 17-4 415Q (415Q-5L)
850 347-046 PK 3.75 CR TD KEVL 17-4 415Q (415Q-5L)
850 345-216 PK 3.75 TC CP KEVL 17-4 415Q (415Q-5L)
850 345-215 PK 3.88 TC CP KEVL 17-4 415Q (415Q-5L)
850 345-214 PK 4.00 TC CP KELV 17-4 415Q (415Q-5L)
850 345-213 PK 4.13 TC CP KEVL 17-4 415Q (415Q-5L)
850 345-212 PK 4.25 TC CP KEVL 17-4 415Q (415Q-5L)
850 345-211 PK 4.38 TC CP KELV 17-4 415Q (415Q-5L)
850 345-210 PK 4.50 TC CP KEVL 17-4 415Q (415Q-5L)
887 181205709 SPACER, VALVE TOOL, L FLUID ENDS
888 1790034 RETRIEVER, CPT BALL & DISC
890 1793007 KIT, 3" VALVE SEAT PULLER
890 1794007 KIT, 4" SEAT PULLER, 415Q-5L & 5M
890 1712342 KIT, VALVE SERVICE TOOL,CAGE TYPE, 415Q-5H
891 1713109 SUPPORT, VALVE PULLER
892 1790042 TOOL, SEAT INST & REM
893 20220194 WASHER
895 1790081 BAR, VALVE PULLER BUMPER
895 20220159 BOLT-PULLER 1"-8 TPI 33" LONG
896 1794006 4" VALVE SEAT PULLER
896 181259300 HEAD, 2.00" ID SEAT PULLER
896 1794006 HEAD, 4" VALVE SEAT PULLER
896 181259409 PULLER HEAD, F/SPHER. VALVE
897 1712242 BAR, CPT BUMPING CAGE TYPE
898 1712263 PLATE, BUMPING BAR INSERT PO-H

415Q5 Plunger Pump Operation Manual

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415Q-5 PLUNGER PUMP

CONTINUOUS DUTY SINGLE ACTING MULTIPLEX PLUNGER PUMP

Document Number Rev

This document contains proprietary and confidential information

NATIONAL OILWELL VARCO

Improvements in design, engineering, materials, production methods, etc., may necessitate

! WARNING ! WARNING ! WARNING !

! WARNING ! WARNING ! WARNING !

! ATTENTION - NOTICE - IMPORTANT !

! WARNING ! WARNING ! WARNING !

1. SHUT DOWN OR DISENGAGE THE PUMP POWER SOURCE.

2. SHUT DOWN ALL PUMP ACCESSORY EQUIPMENT.

OVERHAUL AND REPAIR 11

DIASSEMBLY OF POWER END 12-31

REMOVAL OF WIPER BOX AND INTERMEDIATE RODS 12

REMOVAL OF CRANKCASE COVERS AND CONNECTING ROD CAPS 15

REMOVAL OF CONNECTING ROD AND CROSSHEADS 16

DISASSEMBLY AND REMOVAL OF GEAR REDUCER 18

REMOVAL OF CRANKSHAFT FROM POWER FRAME 21

DISASSEMBLY OF WIPER BOX 27

DISASSEMBLY OF CONNECTING ROD 28

REMOVAL OF STUFFING BOX 32

DISASSEMBLY OF STUFFING BOX 34

SEPARATING THE POWER END FROM THE FLUID END 37

REMOVAL OF VALVE COVERS 39

REMOVAL OF SUCTION AND DISCHARGE VALVES WITH TAPERED VALVE SEATS 41

DISASSEMBLY OF “H” MODEL FLUID END 43-48

REMOVAL OF CAGED VALVE COVERS 43

REMOVAL OF CAGED VALVE ASSEMBY 44

ASSEMBLING THE POWER END 49-75

ASSEMBLING THE CONNECTING ROD AND CROSSHEAD 49

ASSEMBLING THE WIPER BOX 52

ASSEMBLING THE CRANKSHAFT 54

INSTALLATION OF MAIN BEARING RACES ON CRANKSHAFT 59

INSTALLATION OF TAPERED BEARINGS AND BEARING CAGE ON CRANKSHAFT 61

INSTALLATION OF MAIN BEARINGS IN POWER FRAME 64

INSTALLATION OF CONNECTING ROD AND CROSSHEAD IN POWER FRAME 67

COMPLETION OF CONNECTING ROD ASSEMBLY ON CRANKSHAFT 70

COMPLETION OF CRANKSHAFT INSTALLATION 72

INSTALLATION OF WIPER BOX 74

FINAL POWER FRAME ASSEMBLY AND LUBRICATION 75

INSTALLATION OF SUCTION VALVE SEATS 76

INSTALLATION OF VALVE COMPONENTS 77

INSTALLATION OF DISCHARGE VALVE SEATS 79

INSTALLATION OF FLUID END STUDS AND COVERS 82

INSTALLATION OF FLUID END TO POWER FRAME STUDS 84

ASSEMBLING THE MODEL “H” FLUID END 86-95

INSTALLATION OF CAGED VALVE COMPONENTS 86

INSTALLATION OF VALVE COVER AND LOADING BOLT 93

INSTALLATION OF FLUID END TO POWER FRAME STUDS 95

MATING THE FLUID END TO POWER END 96

STUFFING BOX ASSEMBLY AND INSTALLATION 97-110

STUFFING BOX FOR BRAIDED PACKING 97

STUFFING BOX FOR 838 PACKING 102

INSTALLATION OF STUFFING BOX IN PUMP 109

INSTALLATION OF PLUNGER CLAMP 111

MOUNTING GEAR REDUCER AND FINAL ASSEMBLY 113-117

INSTALLATION OF GEAR REDUCER HOUSING 113

INSTALLATION OF GEAR SETS INTO GEAR REDUCER HOUSING 114

INSTALLATION OF POWER END COVERS 117