2S 5S 11D 22T 32T 31Q Multiplex Plunger Pumps Manual

Multiplex Plunger
Pumps
Installation, Care and
Operation Manual
32T-2
22T-2 Covering the

following pumps:
2S-1
5S-2
11D-2
22T-2
32T-2
31Q-2
2S-1/5S-2 Print
11D-2
Index
Next
Sales / Technical Information
USA Tollfree: 1 (800) 324-4706

Phone: 1 (918) 447-4600
Fax: 1 (918) 447-4677
Internet: http://www.nov.com
31Q-2
P.O. Box 4638 Houston, Texas 77210-4638 ISSUE: August 27, 2004
SUPPLEMENT FOR
ALL PUMP MANUALS
! WARNING !
PRESSURE
RELIEF
VALVES
! NOTICE !
Our technical publications relative to

reciprocating pumps state that pressure
relief valves must be installed in the
discharge systems from these units.
This supplement is issued to emphasize
the importance of relieving the discharge
system of all pressure which exceeds the
rated working pressure applied by the
manufacturer to the specific pistons and
liners (or plungers and packing) in any
particular unit.
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! WARNING !
For the protection of persons and property the discharge system from each Reciprocating Pump must be
equipped with a device which relieves the system of all pressures which exceed the pressure rating applied
by the manufacturer to each particular piston or plunger diameter. Allowances will be made for pressure
surges which are inherent with the reciprocating action of piston and plunger pumps. The percentage of
pressure allowance appears later in this publication and in the “Standards of the Hydraulic Institute” (13th
edition).
The relieving device must provide for instantaneous pressure relief, it may be a valve designed for automatic
or manual resetting; however, if preferred, rupture discs or burst discs may be installed.
FAILURE to comply with the procedures outlined in the Warning may result in damage to the pump and
related equipment and more importantly may cause serious bodily injury or death!
THE PRESSURE RELIEF VALVE:
1. This valve must be a full opening type. 3. The relief valve must be between the pump
fluid end and any valve in the discharge
2. It must have a working pressure rating, equal system.
to or greater than, the maximum working
pressure of the pump. 4. There must be no restricting device(s)
between the relief valve and the pump fluid
3. The through capacity of the valve, when fully end.
opened, must be sufficient to relieve the full
capacity of the pump without excessive THE RELIEF VALVE DISCHARGE LINE:
overpressure.
1. The relief valve discharge line should not
RUPTURE DISC OR BURST DISC: terminate in the pump suction line.
1. These discs must have a diameter which is 2. The line should terminate in the supply tank,
not less than the pipe size of the pressure if possible.
relief flange.
3. The line must be securely anchored.
2. These discs must have a rupture or burst
pressure rating consistent with the 4. The line must be the same pipe size as, or
specifications tabulated later in this may be larger than, the discharge connection
publication. on the relief valve.
LOCATION OF THE RELIEF VALVE: 5. If the line is of great length, this must be
taken into consideration in sizing the relief
1. The relief valve must be placed in the valve.
discharge line as close as possible to the
pump fluid end or it may be mounted on the 6. There must be no restrictions or valves in the
pump discharge manifold. relief valve discharge line.
2. The relief valve must be on the pump side of NOTE: Follow the foregoing instructions if
any discharge strainer. rupture discs or burst discs are installed.
SUGGESTED SET PRESSURES FOR THE PUMP RELIEF VALVES:

PUMP TYPE: OPERATING PUMP PRESSURE:
Double Acting – Duplex Piston Pressure Rating – Plus 25%
Double Acting – Triplex Piston Pressure Rating – Plus 10%
Double Acting – Quintuplex Piston Pressure Rating – Plus 10%
Single Acting – Triplex Piston Pressure Rating – Plus 10%
Single Acting – Simplex Plunger Pressure Rating – Plus 25%
Single Acting – Duplex Plunger Pressure Rating – Plus 20%
Single Acting – Triplex Plunger Pressure Rating – Plus 10%
Single Acting – Quintuplex Plunger Pressure Rating – Plus 10%
Single Acting – Septuplex Plunger Pressure Rating – Plus 10%
Note: The above set pressures are to be observed when installing rupture discs or burst discs.

Installation, Care and Operation
Manual
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 dimensions 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 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, beginning at the left side of the pump.
! 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.

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! WARNING ! WARNING ! WARNING !

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:
ALL PUMP SIZES WITHIN THIS MANUAL WILL BE DESCRIBED WITH THE NEW OR CURRENT
NOMENCLATURE. THE OLD PUMP NOMENCLATURES DESCRIBED ON THE FRONT COVER, BUT NOT
INCLUDED IN THIS MANUAL EXCEPT AS NEEDED, ARE TO BE UNDERSTOOD AS BEING INCLUDED WITH THE
NEW NOMENCLATURES.
! WARNING ! WARNING ! WARNING !

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.

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Plunger Pump Nomenclature Example….
22 T- 2 M F
RATED INPUT
HORSEPOWER
T = TRIPLEX
Q = QUINTUPLEX
F = FLANGED, T = THREADED
L = LOW PRESSURE
M = MEDIUM. H = HIGH
STROKE LENGTH (IN.)

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Table of Contents…
INSTALLATION
PAGE
I. GENERAL
A. Suction Line .................................................................................................................................................... 7
B. Discharge Line ............................................................................................................................................. 7-8
C. Power End ...................................................................................................................................................... 8
D. Fluid End......................................................................................................................................................... 8
E. Plunger Packing .............................................................................................................................................. 9
F. Plunger Packing Lubrication ........................................................................................................................... 9
G. Suction Pulsation Dampeners
1. Low Pressure - Plastic Body....................................................................................................................... 9
2. High Pressure - Aluminum Body .............................................................................................................. 10
LUBRICATION
I. GENERAL
A. Oil .................................................................................................................................................................. 11
OPERATION
I. GENERAL
A. Operation Check List .................................................................................................................................... 12
MAINTENANCE
I. GENERAL
A. Daily Maintenance ........................................................................................................................................ 13
B. Monthly Maintenance.................................................................................................................................... 13
C. Storage ......................................................................................................................................................... 14
D. Start-Up After Storage .................................................................................................................................. 14
II. TROUBLE SHOOTING GUIDE...................................................................................................................... 15-16
OVERHAUL AND REPAIR

I. GENERAL
A. Tools Required.............................................................................................................................................. 17
B. Check Points and Adjustments
1. 2S-1 & 5S-2 .............................................................................................................................................. 17
2. 11D-2, 22T-2, & 32T-2.............................................................................................................................. 17
3. 31Q-2........................................................................................................................................................ 17
4. 2S-1, 5S-2, 11D-2, 22T-2, 32T-2, & 31Q-2 ......................................................................................... 17-18
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Table of Contents (Continued)…

DISASSEMBLY
PAGE
I. POWER END
A. Plunger/Intermediate Rods and Oil Wiper Retainers (All Pumps).................................................................19
B. Crankshaft Assembly
1. 2S-1, 5S-2, 11D-2, 22T-2, & 32T-2 ...........................................................................................................20
2. 31Q-2.........................................................................................................................................................20
C. Crankshaft Bearings (All Pumps) ..................................................................................................................20
II. FLUID END

A. Fluid Cylinder Removal (All Pumps) ..............................................................................................................21
B. Plunger Removal (All Pumps)........................................................................................................................21
C. Stuffing Box Removal (All Pumps) ................................................................................................................21
D. Fluid End Valve Removal ..............................................................................................................................21
ASSEMBLY
I. POWER END
A. Connecting Rod and Crosshead Assembly (All Pumps) ...............................................................................22
B. Crankshaft Main Bearings and Center Support Bearings
1. 2S-1, 5S-2, 11D-2, 22T-2, & 32T-2 ..................................................................................................... 23-24
2. 31Q-2................................................................................................................................................... 24-25
C. Connecting Rod to Crankshaft Assembly (All Pumps) ..................................................................................26
D. Intermediate Rods and Oil Seal Retainers (All Pumps) ................................................................................26
II. FLUID END

A. Stuffing Boxes and Plungers (All Pumps)......................................................................................................27
B. Power End/Fluid End Adapters (All Pumps)............................................................................................ 27-28
C. Fluid Cylinders (All Pumps) ...........................................................................................................................28
D. Fluid Valves – Tapered Seat (All Pumps) .....................................................................................................28
E. Piping Installation (All Pumps) .......................................................................................................................28
F. Plunger Packing Installation
1. 838 Packing......................................................................................................................................... 29-30
2. Braided Packing .................................................................................................................................. 31-32
3. 1068-4 Spring Loaded Packing........................................................................................................... 33-34
VALVE SECTION ............................................................................................................................. 35-48

LUBRICATOR ...................................................................................................................................... 49-50
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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 plant. 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° ells 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. SUCTION LINE
1. The suction line must not be smaller than the suction intake of the fluid cylinder 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.
2. When bends are required, they should be made with long radius 45° ells. Do not use a bend directly adjacent to
the fluid cylinder. Avoid using any 90° bends 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.
B. 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
cylinder 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° ell. Do not use a bend directly adjacent to
the fluid cylinder, particularly a 90° bend.

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Installation…
I. GENERAL
B. DISCHARGE LINE (Continued…)
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 25% 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.
C. POWER END
1. The pump must be mounted level and should be grouted in and 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, place the pump in a strain, 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 Thomas Flexible 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
page 11) 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.
D. FLUID END
1. The fluid cylinder is shipped assembled to the pump complete with valves and cover plates. 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.

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Installation…
I. GENERAL (Continued)…
E. 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 pages 29 through 34 for correct procedure for
packing used.
F. 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 feed five to seven drops per
minute.
G. SUCTION PULSATION DAMPENERS
1. Low Pressure - Plastic Body
a. Some National Oilwell Varco plunger pumps are equipped with suction pulsation dampeners. These
dampeners do an excellent job when properly charged and should be kept filled during operation.
! ATTENTION !
At suction pressures over 10 psi (.7kg/cm2), the dampener should be deflated prior to bleeding off the suction
pressure to prevent damage to the diaphragm.
b. The plastic dampener body has an instruction decal attached, which lists the following installation and
charging procedures:
! ATTENTION !
HANDLE WITH CARE.
This is a plastic part and can be broken.
c. Tighten capscrews with 10 to 12ft-lbs. of torque.
! ATTENTION !
Use thread-sealing compound on check valve and tighten until snug.
OVERTIGHTENING WILL DAMAGE BODY.
d. With pump operating - Charge dampener until bottom of diaphragm is visible through sight glass. Proper
charge is when bottom of diaphragm is between center and top of sight glass.

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Installation…
I. GENERAL
G. SUCTION PULSATION DAMPENERS (Continued)…
2. High Pressure - Aluminum Body
a. In pressures in excess of 20 psi (1.406 kg/cm2 ) and up to 70 psi (10.545 kg/cm2), it is necessary to use the
National Oilwell Varco high-pressure suction dampener.
b. The high-pressure dampener is charged in a similar manner to the low-pressure plastic dampener, using air or
nitrogen to charge the diaphragm and maintain its position in relation to the sight glass.
c. The following procedures should be used to service this dampener:
(1) The dampener is fitted to an adapter that may be either welded into an existing line or be a part of a
separate dampener housing. Place a gasket on each side of the diaphragm retaining plate and place on
the adapter.
(2) The dampener spacer is then placed on top of the retainer plate with the grooved side up and the flat side
against the retainer gasket.
(3) The diaphragm fits into the groove on the spacer with the curved portion of the diaphragm above the
spacer.
(4) Apply a continuous 1/8" diameter bead of silicone rubber on the outer edge of the diaphragm after it has
been positioned into the spacer. This silicone rubber (GE Silicone Rubber or Dow-Corning Silastic) is
readily available at most hardware stores. Assemble the body cover within 10 minutes after applying the
silicone rubber.
(5) Fit the dampener cover over the diaphragm and assemble the capscrews. Tighten these capscrews
evenly to approximately 80 ft-lbs. of torque.
(6) Install the sight glasses, one in each side of the cover. Be sure to seat the sight glass packing carefully
into the groove on the cover, as this must be an airtight connection.
(7) The air check valve has a pipe thread and must be made up into the cover airtight. Use a good pipe
thread sealant to promote sealing.

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Lubrication…
I. GENERAL
NATIONAL OILWELL VARCO Plunger Pumps are "splash" lubricated. The main bearings and crankshaft bearings
are fed by splash. 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.
A. OIL
Use "extreme pressure" gear oil. The chart below shows the recommended grades for various temperatures
surrounding the pump.
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: 2S-1 – 2 5S-2 – 2 11D-2 – 3-1/2

22T-2 – 5 32T-2 – 5 31Q-2 – 8
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: 2S-1 – 1.9 5S-2 – 1.9 11D-2 – 3.3

22T-2 – 4.7 32T-2 – 4.7 31Q-2 – 7.6
Oil must pour freely at minimum operating temperature. Change oil every six months or as frequently as
operating conditions require to maintain a clean, sludge-free oil of proper viscosity.

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Operation…
I. GENERAL
! ATTENTION !
THE FOLLOWING POINTS SHOULD BE CHECKED FOR THE PREVENTION OF TROUBLE OR TO
CORRECT TROUBLE THAT MAY ARISE.
A. 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 previous).
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 pages 29 to 34).
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.

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Maintenance…
I. GENERAL
The following points are intended as a guide to be used in setting up a maintenance program. Good preventive
maintenance will pay big dividends in the form of reliable service with a minimum of trouble.
A. DAILY MAINTENANCE
1. Check power end oil level daily. Do not attempt to check the oil 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 rod. Check for plunger
packing leakage.
2. Lubricate 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 at pressures above 1200 psi. Use an alternate
packing lubricator to drip the proper oil of the plunger for lubrication. (See page 9 for further details).
3. Check lubricator for proper level and operation.
4. Check plunger packing for excessive leakage. Replace packing as required.
5. Check stuffing box adjusting nuts for tightness.
6. Drain plunger leakage sump tanks if required.
7. Flush plunger chamber drain lines with kerosene on power oil pumps and fresh water on salt pumps. This may
be done weekly unless salt and paraffin accumulation is severe.
8. Make sure suction and discharge line valves are fully open.
9. Check for leakage between the fluid cylinder and frame or stuffing box to fluid cylinder packing if required.
10. Check all seals for leakage.
11. Check belts or clutch for slippage. If either condition exists, correct immediately.
B. MONTHLY MAINTENANCE
1. Drain and refill crankcase every six (6) months or as often as required to maintain a clean, sludge-free oil of the
proper viscosity.
2. Clean crankcase air breather with a non-explosive solvent.
3. Check all studs, nuts and capscrews for tightness. Inspect gaskets for leaks; tighten or replace as required.
4. Clean pump. Good housekeeping is a prerequisite to good maintenance.

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Maintenance…
I. GENERAL (Continued)…
C. STORAGE
If the pump is to be idle for longer than one (1) week, it should be prepared for storage as follows:
1. Drain and clean crankcase thoroughly. Leave drain open and install 90° elbow, pointing downward, to permit air
circulation and prevent condensation build-up.
2. Coat all bearings, finished surfaces, and entire inside surface of crankcase with a rust inhibiting oil.
3. Remove plungers and packing, clean and coat with rust inhibiting oil.
4. Remove fluid cylinder valves allowing cylinder to be thoroughly cleaned and drained.
5. Coat entire cylinder, valves and parts, with a rust inhibiting oil.
6. Thoroughly inspect pump and rotate crankcase once each month. Re-coat with rust inhibiting oil where
necessary.
D. START-UP 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 properly in place.
! ATTENTION !
FAILURE TO OBSERVE THE FOLLOWING POINTS CAN RESULT IN SERIOUS DAMAGE.
1. Remove all covers on both power end and fluid end; thoroughly clean and inspect all parts and finished
surfaces.
2. Check all bearings to make sure they are clean and in good condition.
3. Make sure valves, plungers and packing are properly installed and in good condition.
4. Carefully tighten all bolts, nuts, studs and working connections.
5. Fill power end to the proper level with clean oil of the proper viscosity. Make sure oil is poured into the
crosshead reservoir and is worked into all bearings.
6. Fill packing lubricator and pump lines full. Check by breaking connection at stuffing box, working lubricator
plunger until oil appears.

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Maintenance (Continued)…
II. TROUBLE SHOOTING GUIDE
PROBLEM POSSIBLE CAUSE CORRECTION

SUCTION LINE RESTRICTED BY:
(1, 2, 3, 4)
1. TRASH, SCALE BUILD UP, ETC. LOCATE AND REMOVE
2. PARTIALLY CLOSED VALVE IN SUCTION
LOCATE AND CORRECT
LINE
3. METERS, FILTERS, CHECK VALVES, NON-
FULL-OPENING, CUT-OFF VALVE OR OTHER RE-WORK SUCTION LINE TO ELIMINATE
RESTRICTIONS
4. SHARP 90º BENDS OR 90º BLIND TEES. RE-WORK SUCTION LINE TO ELIMINATE.
AIR ENTERING SUCTION LINE THROUGH CUT-
TIGHTEN OR REPACK VALVE STEM PACKING
OFF VALVE
AIR ENTERING SUCTION LINE THROUGH
LOCATE AND CORRECT
LOOSE CONNECTION OR FAULTY PIPE
LOCATE RISE OR TRAP AND CORRECT BY
AIR OR VAPOR TRAPPED IN SUCTION LINE STRAIGHTENING LINE, PROVIDING ENOUGH SLOPE
TO PERMIT ESCAPE AND PREVENT BUILD-UP
KNOCKING OR LOW FLUID LEVEL
INCREASE SUPPLY AND INSTALL AUTOMATIC LOW
POUNDING IN FLUID LEVEL SHUT-DOWN SWITCH
END AND PIPING SUCTION DAMPENER NOT OPERATING INSPECT AND REPAIR AS REQUIRED
WORN VALVES INSPECT AND REPAIR AS REQUIRED
ENTRAINED GAS IN FLUID PROVIDE GAS BOOT OR SCRUBBER FOR FLUID
INLET TO BE AT TOP OF TANK AND BAFFLED TO
BREAKOUT GAS AND PREVENT CHANNELING.
POOR INLET AND OUTLET ARRANGEMENT AT
OUTLET TO BE 12" FROM BOTTOM OF TANK AND AS
SUPPLY TANK
FAR FROM INLET AS POSSIBLE, NEVER CLOSER THAN
90º
LOOSE PACKING ADJUSTING NUT TIGHTEN AND/OR REPLACE PACKING
REPLACE WITH INDIVIDUAL SUCTION LINE OF NEXT
INADEQUATE SIZED SUCTION LINE
SIZE LARGER THAN INLET PUMP
LEAKAGE PRESSURE RELIEF VALVE THAT HAS REPAIR VALVE AND RE-WORK PIPING TO RETURN TO
BEEN PIPED BACK INTO SUCTION LINE SUPPLY TANK - NOT SUCTION LINE
REWORK TO RETURN BY-PASSED FLUID BACK TO
BY-PASS PIPED BACK TO SUCTION
SUPPLY TANK - NOT SUPPLY LINE
INSPECT WHEN ROTATING PUMP BY HAND AND
BROKEN PLUNGER
REPLACE AS REQUIRED
VALVE WEAR OR DAMAGE CHECK FLUID END FOR BAD VALVES
WORN MAIN BEARINGS REPLACE AS REQUIRED
LOOSE PLUNGER - INTERMEDIATE ROD INSPECT FOR DAMAGE - REPLACE AS REQUIRED AND
KNOCK IN POWER END
CROSSHEAD CONNECTION TIGHTEN
WORN CROSSHEAD PIN, OR CONNECTING
LOCATE AND REPLACE AS REQUIRED
ROD

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Maintenance…
II. TROUBLE SHOOTING GUIDE (Continued)…
PROBLEM POSSIBLE CAUSE CORRECTION

CORROSION TREAT FLUID AS REQUIRED
ABRASIVES IN FLUID FILTER AS REQUIRED
INSPECT AND INSTALL PER INSTRUCTION SHEET IN
IMPROPER INSTALLATION
PACKING BOX
RAPID VALVE WEAR IMPROPER LUBRICATION (EITHER
CHECK INSTRUCTIONS IN MANUAL AND CORRECT AS
OR FAILURE INSUFFICIENT OR EXCESSIVE OR INCORRECT
REQUIRED
TYPE)
LUBRICATOR NOT OPERATING INSPECT AND CORRECT AS REQUIRED
ADJUSTING NUT LOOSE INSPECT AND REPACK PER INSTRUCTIONS
SCALE OR BUILD UP ON PLUNGER TREAT FLUID AS REQUIRED
WORN OR PITTED PLUNGERS AND/OR
REPLACE AS REQUIRED
STUFFING BOX
ABRASIVES IN FLUID FILTER AS REQUIRED
CHECK SYSTEM FOR FAULTY LOW-LEVEL SHUTDOWN
PUMP OPERATED WITHOUT FLUID CONTROLS OR CLOSED VALVES AND CORRECT AS
REQUIRED
SHORT PACKING LIFE
CHECK WITH MANUFACTURER FOR
ABNORMALLY HIGH FLUID TEMPERATURES
RECOMMENDATIONS ON TYPE OF PACKING
WRONG TYPE OF PACKING FOR PARTICULAR CHECK WITH MANUFACTURER FOR
FLUID BEING HANDLED RECOMMENDATIONS ON TYPE OF PACKING
CAVITATION (KNOCKING AND POUNDING IN REFER TO CORRECTION OF "KNOCK IN POWER END"
FLUID CYLINDER AND PIPING) ABOVE
INSTALL NEW PLUNGER USING CARE TO AVOID ANY
PLUNGER CRACKED AT INSTALLATION
SHARP BLOW OR FORCE ON PLUNGER.
CHECK SYSTEM TO ELIMINATE ANY SHARP OR
BROKEN OR PITTED SUDDEN TEMPERATURE DIFFERENCES.
FROM IMPLOSIONS TEMPERATURE EXTREMES ON THE PLUNGER CAN
PLUNGER CRACKED FROM THERMAL SHOCK
CAUSED BY IN OCCUR FROM PACKING AS DISCUSSED UNDER
EXCESSIVE GAS OR “SHORT PACKING LIFE” PROBLEM PR FROM
AIR ENTRAINED FLUID TEMPERATURE CHANGES IN THE FLUID ITSELF
PLUNGER PITTED FROM IMPLOSIONS CAUSED CHANGE SUCTION SYSTEM TO ELIMINATE OR CHECK
BNY EXCESSIVE GAS OR AIR ENTRAINED IN WITH MANUFACTURING REGARDING USE OF SPECIAL
FLUID. PACKING ARRANGEMENT
CHECK AND CORRECT PER RECOMMENDATIONS
PACKING FAILURE
RAPID WEAR OF HARD UNDER “SHORT PACKING LIFE” PROBLEM
COATED PLUNGER PLUNGER NOT SUITABLE FOR PARTICULAR CHECK WITH MANUFUFACTURING FOR
SERVICE RECOMMENDATION
PLUNGER NOT SUITABLE FOR PARTICULAR
CHECK AND CORRECT AS REQUIRED
SERVICE
PUMP NOT LEVEL CHECK AND CORRECT AS REQUIRED
OIL SEAL LEAKS WORN, CORRODED, PITTED, OR OTHERWISE
CHECK AND CORRECT AS REQUIRED
DAMAGED SEALING SURFACE
WORN OR DAMAGED SEALS CHECK AND CORRECT AS REQUIRED
OIL LEVEL TOO HIGH CHECK AND CORRECT AS REQUIRED

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Overhaul and Repair…

I. GENERAL
The bearings and other working parts in the power end have been designed for continuous duty, and if properly
lubricated, will provide years of trouble-free service. However, after the pump has been in service for a long period
of time, the bearings and other working parts will gradually loosen, and if not corrected, will lead to more serious
trouble. The time to overhaul the pump will vary; depending on the operating conditions, and is therefore a matter
that must be left to the good judgment of the operator. Complete disassembly and assembly procedures are
discussed in their respective sections.
A. TOOLS REQUIRED
Most of the tools required to overhaul the pump will be found in an ordinary set of mechanics hand tools. The
special tools and equipment required, and not furnished, with the pump include a torque wrench, bearing puller, and
a valve servicing kit. Also, a hot oil bath capable of reaching a temperature of 300°F (149°C) will be needed.
B. CHECK POINTS AND ADJUSTMENTS
1. 2S-1 & 5S-2:
The crankshaft main bearings are single row; shim adjusted, tapered roller bearings. They have been
assembled and adjusted at the factory with proper clearance and will give long trouble-free service. The proper
clearance is found by adjusting the amount of shims until the crankshaft has .001" to .003" endplay and will
rotate freely.
2. 11D-2, 22T-2, & 32T-2:
The crankshaft main bearings are single row; shim adjusted, tapered roller bearings. They have been
assembled and adjusted at the factory with proper clearance and will give long trouble-free service. The proper
clearance is found by adjusting the amount of shims until the crankshaft has .002" to .004" endplay and will
rotate freely.
3. 31Q-2:
The 31Q-2 has two single rows, shim adjusted, tapered roller end bearings. They have been assembled and
adjusted at the factory with proper clearance and will give long trouble-free service. The proper end clearance
is found by adjusting the amount of shims until the crankshaft has .004" to .006" endplay and will rotate freely.
The 31Q-2 also has two steel backed Babbitt center mains which are non adjustable. The center mains should
have .010” to .018” (.254 mm to .457 mm) total diametrical clearance. This is non adjustable.
4. 2S-1, 5S-2, 11D-2, 22T-2, 32T-2, & 31Q-2:
a. The connecting rod shell bearings or inserts are precision made steel backed Babbitt lined and require no
shims for adjustment. Tolerances are listed on the following page.
b. The normal clearance between the crosshead and crosshead bore is .003” (.076 mm) to .009” (229 mm).
The maximum allowable clearance, including wear, is .012” (.305 mm).
c. The wrist pin bushings must be pressed into the connecting rods and reamed to size. The allowable
clearance between the pin and bushing is listed on the following page.

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Overhaul and Repair…

I. GENERAL
B. CHECK POINTS AND ADJUSTMENTS (Continued)…
CRANKSHAFT O.D MAXIMUM CLEARANCE MINIMUM CLEARANCE

PUMP
in mm in mm in mm
2S-1 2.125 53.975
.004 .102 .002 .051
5S-2 2.124 53.950
2.125 53.975
11D-2 .004 .102 .002 .051
2.124 53.950
22T-2 2.125 53.975
.004 .102 .002 .051
32T-2 2.124 53.950
2.125 53.975
31Q-2 .004 .102 .002 .051
2.124 53.950
CROSSHEAD PIN O.D. MAXIMUM CLEARANCE MINIMUM CLEARANCE

PUMP
in mm in mm in mm
2S-1 .9380 23.825
.002 .051 .001 .025
5S-2 .9375 23.813
.9380 23.825
11D-2 .002 .051 .001 .025
.9375 23.813
22T-2 2.5635 65.113
.002 .051 .001 .025
32T-2 2.5300 65.100
3.0015 76.238
31Q-2 .002 .051 .001 .025
3.0010 76.225

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Disassembly…
I. POWER END
It is not necessary to remove the fluid end when disassembling the power end. However, the plungers should be
removed through the fluid end cylinder heads. The plungers and intermediate rods are one piece on all class fluid
ends, except the “H” models. The “H” models have separate intermediate rods.
! ATTENTION !
POWER END DISASSEMBLY AND OVERHAUL IS BEST PERFORMED IN A WELL EQUIPPED SHOP
ENVIROMENT. IF THE PUMP IS DISASSEMBLED AT LOCATION INSURE THE PRESSURE HAS BEEN
REMOVED FROM THE FLUID END AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES.
INSURE THE FLUID END IS DRAINED AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE
PROCEEDING!
A. PLUNGER/INTERMEDIATE RODS AND OIL WIPER RETAINERS (ALL PUMPS)
1. Remove the fluid end cylinder head.
2. Loosen the packing gland nuts.
3. If the pump has intermediate rods a back-up wrench is required. The plunger and intermediate rod separate at
the knurl area interface. Using the back-up wrench break the plunger loose and unscrew from the intermediate
rod. Remove the plunger through the fluid cylinder opening.
4. Using a pipe wrench on the knurled area of the intermediate rod, remove it from the crosshead and power end.
5. If the pump does not have an intermediate rod, use a pipe wrench on the knurled area of the plunger and break
it loose from the crosshead. Unscrew and remove through the fluid cylinder opening.
6. Remove the two nuts holding the wiper box gland and remove the gland.
7. Slide the wiper box and seal assembly out of the power end.

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Disassembly…
I. POWER END (Continued)…
B. CRANKSHAFT ASSEMBLY
1. 2S-1, 5S-2, 11D-2, 22T-2, & 32T-2
a. Remove the rear power end crankcase cover.
b. Remove connecting rod bolts and cap.
NOTE: Connecting rods and caps are matched marked and must be kept together. Do not mix caps and rods.
c. Connecting rod and crosshead must be moved all the way forward to clear crankshaft.
d. Remove crankshaft bearing retainers, seals, and shims. These parts should be tied together and marked
for reassembly at their original location. There are two tapped holes in each bearing housing that can be used
to jack the housing out.
! ATTENTION !
COVER KEYWAYS TO PROTECT OIL SEALS DURING REMOVAL.
e. Carefully remove the crankshaft out either side of the power frame. If reusing the end bearings remember,
the crankshaft end bearing cones and cups are matched sets. Do not mix cones and cups.
2. 31Q-2
a. Remove the rear power end crankcase cover.
b. Remove connecting rod bolts and cap.
NOTE: Connecting rods and caps are matched marked and must be kept together. Do not mix caps and rods.
c. Connecting rod and crosshead must be moved all the way forward to clear crankshaft.
d. Remove crankshaft bearing retainers, seals, and shims. These parts should be tied together and marked
for reassembly at their original location. There are two tapped holes in each bearing housing that can be used
to jack the housing out.
e. Carefully remove the crankshaft out either side of the power frame. If reusing the end bearings remember,
the crankshaft end bearing cones and cups are matched sets. Do not mix cones and cups.
C. CRANKSHAFT BEARINGS (ALL PUMPS)
The crankshaft main bearings may be inspected while on the crankshaft and should not be removed unless necessary.
A puller is required when replacement is necessary.
NOTE: Keep the component parts of the bearings together if they are to be re-installed. They are match marked and
must be correctly assembled as a unit.

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Disassembly (Continued)…
II. FLUID END
! ATTENTION !
BEFORE WORKING ON THE FLUID END ENSURE THE PRESSURE HAS BEEN REMOVED FROM THE FLUID END
AND THE PUMP BLOCKED OUT WITH APPROPRIATE BLOCK VALVES. ENSURE THE FLUID END IS DRAINED
AND ANY POWER SOURCE OR DRIVER IS LOCKED OUT BEFORE PROCEEDING!
A. FLUID CYLINDER REMOVAL (ALL PUMPS)
1. Disconnect piping.
2. Remove the plungers as described below.
3. Remove the hex nuts holding the fluid end to the power end and slide cylinder forward until free.
B. PLUNGER REMOVAL (ALL PUMPS)
1. Remove the fluid end cylinder head.
2. Loosen the packing gland nuts.
3. Rotate the crankshaft until the knurl area of the plunger/intermediate rod is accessible in the cradle area of the pump.
4. If the pump has intermediate rods a back-up wrench is required. The plunger and intermediate rod separate at the
knurl area interface. Using the back-up wrench break the plunger loose and unscrew from the intermediate rod.
Remove the plunger through the fluid cylinder opening.
5. If replacing the intermediate rod, use a pipe wrench on the knurled area of the intermediate rod and remove it from the
crosshead and power end.
6. If the pump does not have an intermediate rod, use a pipe wrench on the knurled area of the plunger and break it
loose from the crosshead. Unscrew and remove through the fluid cylinder opening.
C. STUFFING BOX REMOVAL (ALL PUMPS)
Most pumps in this series have integral stuffing boxes. A few models do have separate stuffing boxes. On these pumps the
stuffing box is clamped between the fluid end body and the power frame. The fit on the fluid end side is a slip fit. The fit on the
power end side is a slight press. To remove the stuffing boxes follow this procedure.
1. Remove the plungers and fluid end as previously described.
2. Remove any lube fittings, etc.
3. Support the box with a lifting strap
4. Use a heavy brass bar and drive the box out of the power frame opening.
D. FLUID END VALVE REMOVAL
Refer to valve section located in the middle of this manual.

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Assembly…
I. POWER END
A. CONNECTING ROD AND CROSSHEAD ASSEMBLY (ALL PUMPS)
1. Press the crosshead pin bushing into the connecting rod.
2. Ream bushing to obtain the clearance listed on page 18. (If service bushings are used, reaming will not be
necessary in most cases).
3. Assemble the connecting rod to the crosshead by pressing the crosshead pin into the crosshead. Or to facilitate
assembly, the crosshead may be heated to no more than 300°F (149°C) in an electric oven or bath.
NOTE: Crossheads have an oil groove on the topside. Connecting rods and bearing caps are match marked as
units. The rod also has a lube hole on the topside. Install connecting rod in crosshead so the lube hole on the rod
and the oil groove on the crosshead correspond. The oil groove and lube hole go up when installing in the power
frame. See figure 1.
4. Lubricate the crosshead bore and slide the connecting rod crosshead assembly into the power frame. Push the
assemblies all the way forward.
Figure 1

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Assembly…
B. CRANKSHAFT AND MAIN BEARINGS
1. 2S-1, 5S-2, 11D-2, 22T-2, & 32T-2
a. Thoroughly clean and remove all burrs from the I.D. of the cone and roller assembly and from the bearing
seating surfaces on the crankshaft.
b. Heat the cone and roller assembly in an electric oven or oil bath to 300°F (149°C). It is recommended that a
thermometer be used to prevent overheating.
c. After the bearings have been brought up to temperature and with the crankshaft firmly supported, install the
cone and roller assemblies on the crankshaft. Make sure the cone and roller assemblies are firmly against the
shoulders on the crankshaft.
d. Allow the crankshaft and bearing assembly to cool before installing in the power end.
e. Make sure the main bearing openings in the frame are clean and free of burrs.
NOTE: The crossheads and connecting rods must be installed prior to replacing the crankshaft assembly.
f. Install the crankshaft main bearing outer races or cups in the main bearing housing. These races can be
carefully driven into the housing with a brass rod. An alternative and easier way is to chill the races in a freezer
or with CO2 and place them in their respective bearing housings. Ensure the races are completely seated.
g. Place the crankcase main bearing shims, amounting to approximately .100" (2.54 mm) in thickness, on the
crankshaft-bearing housing/retainers. If the old bearings and retainers are being re-installed, use the same
amount of shims as before.
h. Install the off-drive side bearing housing with shims in the power frame and tighten in place with the proper
capscrews.
i. With the cone and roller assemblies of the main bearings in place on the crankshaft, slide the crankshaft
through the main bearing openings in the power end frame with No. 1 throw forward. Slide the off drive side
bearing into its bearing housing and race.
j. Assemble the drive side crankshaft-bearing housing/retainer and shims to the main frame and tighten in place
with the proper capscrews.
NOTE: The following steps, k.1) and k.2) are necessary only if new bearings are being installed. When the
same crankshaft main bearings are being reassembled, use the same amount of shims as were previously
used and use the steps as a check for adjustment.

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Assembly…
I. POWER END
1. 2S-1, 5S-2, 11D-2, 22T-2, & 32T-2 (Continued)…
k. To determine the correct amount of shims when installing new bearings, the following steps are recommended.
1) When first installing shims, use only enough shims to produce a slight drag when the crankshaft is
rotated. Tap shaft on each end sufficient to ensure that the bearing outer race is tightly against the
retainer.
2) Then, add enough shims to remove the slight drag or pre-load (approximately .005" [.127 mm] to .007"
[.178 mm]), depending on the amount of pre-load). The bearings are correctly adjusted when the
endplay of the crankshaft is per the specifications and the crankshaft will rotate freely. Do not pre-load
bearings.
CRANKSHAFT END PLAY
PUMP MAXIMUM END PLAY MINIMUM END PLAY

in mm in mm
2S-1
.003 .076 .001 .025
5S-2
11D-2 .004 .102 .002 .051
22T-2
.004 .102 .002 .051
32T-2
31Q-2 .006 .152 .004 .102
2. 31Q-2
a. Thoroughly clean and remove all burrs from the I.D. of the cone and roller assembly and from the bearing
seating surfaces on the crankshaft.
b. Heat the cone and roller assembly in an electric oven or oil bath to 300°F (149°C). It is recommended that a
thermometer be used to prevent overheating.
c. After the bearings have been brought up to temperature and with the crankshaft firmly supported, install the
cone and roller assemblies on the crankshaft. Make sure the cone and roller assemblies are firmly against the
shoulders on the crankshaft.
d. Allow the crankshaft and bearing assembly to cool before installing in the power end.
e. If installing new steel backed Babbitt lined center mains, install them at this time as described below.
1) Chill the bearings in a freezer or with CO2.
2) Carefully install the center mains.
3) Allow the center mains to warm before proceeding.

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Assembly…
I. POWER END
2. 31Q-2 (Continued)…
4) If you do not have a method to chill the bearings, they can be driven in place with a brass bar or pulled into
place with a bearing installation tool. When using this method take care to not damage the bearing surface
and remove any slight raised spots or burrs that occur from installation before proceeding.
f. Make sure the main bearing openings in the frame are clean and free of burrs.
NOTE: The crossheads and connecting rods must be installed prior to replacing the crankshaft assembly.
g. Install the crankshaft main bearing outer races or cups in the main bearing housing. These races can be
carefully driven into the housing with a brass rod. An alternative and easier way is to chill the races in a freezer
or with CO2 and place them in their respective bearing housings. Ensure the races are completely seated.
h. Place the crankcase main bearing shims, amounting to approximately .100" (2.54 mm) in thickness, on the
crankshaft-bearing housing/retainers. If the old bearings and retainers are being re-installed, use the same
amount of shims as before.
i. Install the off-drive side bearing housing with shims in the power frame and tighten in place with the proper
capscrews.
j. With the cone and roller assemblies of the main bearings in place on the crankshaft, carefully slide the
crankshaft through the main bearing openings in the power end frame with No. 1 throw forward. Slide the
off drive side bearing into its bearing housing and race.
k. Assemble the drive side crankshaft-bearing housing/retainer and shims to the main frame and tighten in place
with the proper capscrews.
NOTE: The following steps, l.1) and l.2) are necessary only if new bearings are being installed. When the
same crankshaft main bearings are being reassembled, use the same amount of shims as were previously
used and use the steps as a check for adjustment.
l. To determine the correct amount of shims when installing new bearings, the following steps are recommended.
1) When first installing shims, use only enough shims to produce a slight drag when the crankshaft is
rotated. Tap shaft on each end sufficient to ensure that the bearing outer race is tightly against the
retainer.
2) Then, add enough shims to remove the slight drag or pre-load (approximately .005" [.127 mm] to .007"
[.178 mm]), depending on the amount of pre-load. The bearings are correctly adjusted when the
endplay of the crankshaft is per the specifications and the crankshaft will rotate freely. Do not pre-load
bearings.
3) After installation the center mains should have .005” (.127 mm) to .009” (.229 mm) clearance per side or
.010” (.254 mm) to .018” (.457 mm) clearance on the diameter.

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Assembly…
C. CONNECTING ROD TO CRANKSHAFT ASSEMBLY (ALL PUMPS)
1. Thoroughly clean and remove all burrs and nicks from connecting rod and crankshaft journals.
2. Position the No. 1 crankshaft throw to the rear.
3. Take a shell bearing half and carefully locate it in the rod half of the connecting rod assembly. Note: the upsets on
the bearings and the notches in the connecting rod must match.
4. Lubricate the connecting rod pin and rod bearing.
5. Slide the connecting rod back over the crankshaft throw using caution so the outer surface of the insert is not
damaged. Note: the match numbers of the cap and rod to be certain the rod is assembled correctly.
7. Install the two (2) capscrews and torque as shown in chart.
TORQUE: FT-LBS
2S-1 22T-2
PUMP 11D-2 31Q-2
5S-2 32T-2
Cast Iron rods 18-24 18-24 18-24 18-24
Aluminum rods 12-16 12-16 12-16 12-16
The connecting rod bearings are precision fitting inserts requiring no adjustment. When re-installing the same
inserts, assemble them in pairs at their original location. Make sure the match marks on the connecting rod and cap
are the same on the corresponding sides.
D. INTERMEDIATE RODS AND OIL SEAL RETAINERS (ALL PUMPS)
The power end wiper box is held in the power frame by two adjustment studs and the wiper box gland. The wiper box
seals are a set of V-ring seals and should be installed with the lips turned toward the crosshead. To replace the seals
follow the instructions below.
1. Clean the stuffing box and gland.
2. Take a new set of seals, lubricate the seals, and install with the lips facing the crosshead.
3. Place the stuffing box back in the power frame.
4. Install the follower and loosely install the gland. Do not tighten until the plunger or adapter rod is reassembled.

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Assembly (Continued)…
II. FLUID END
A. STUFFING BOXES AND PLUNGERS (ALL PUMPS)
Plungers are available in ceramic or steel.
! ATTENTION !
NATIONAL OILWELL VARCO DOES NOT RECOMMEND THE USE OF CERAMIC PLUNGERS FOR PUMPING
FLAMMABLE OR HAZARDOUS LIQUIDS.
1. If the pump has separate stuffing boxes, thoroughly clean and remove any nicks or burrs from all mating surfaces
of the main frame, fluid cylinder and stuffing boxes.
2. Insert stuffing boxes into main frame.
NOTE: The stuffing box is a press fit in the main frame and will have to be driven into position. As an alternative
you can chill the stuffing box in a freezer or with CO2.
! ATTENTION !
PREVENT DAMAGE BY PLACING A BLOCK OF WOOD OVER THE STUFFING BOX FACE.
3. Insert seals (stuffing box to fluid cylinder) into grooves in the face of the stuffing boxes. Grease lightly to hold in
place until fluid cylinder is installed.
4. Assemble packing in stuffing box bore as per instructions included with each set of packing, or as described on
pages 29 to 34.
5. Torque adapter rods, if applicable, or plungers and torque to 30 ft.-lbs.
B. POWER END/FLUID END ADAPTERS (ALL PUMPS)
If the pump has integral stuffing boxes, a power end to fluid end adapter is used. The adapter is a press fit into the
power frame. The adapter is used to locate the fluid end and contains the threads for the packing gland nut.
1. Thoroughly clean and remove any nicks or burrs from all mating surfaces of the main frame, fluid cylinder and
adapters.
2. Insert adapters into main frame.
NOTE: The adapter is a press fit in the main frame and will have to be driven into position. As an alternative you
can chill the adapter in a freezer or with CO2.

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Assembly…
II. FLUID END
B. POWER END/FLUID END ADAPTERS (ALL PUMPS) (Continued)…
! ATTENTION !
PREVENT DAMAGE BY PLACING A BLOCK OF WOOD OVER THE ADAPTER FACE.
3. Insert the O-Ring into the groove on the adapter face. Grease lightly to hold in place until fluid cylinder is
installed.
C. FLUID CYLINDER (ALL PUMPS)
1. Carefully slide fluid end body into place. Ensure stuffing box or adapter seals are not pinched as cylinder is
moved into place.
2. Tighten nuts alternately, pulling fluid cylinder up evenly; torque nuts to the following values:
2S-1 22T-2
THREADS 11D-2 31Q-2
5S-2 32T-2
Lubricated (ft-lbs) 95 150 150 95
D. FLUID VALVES - TAPERED SEAT TYPE (ALL PUMPS)
See Valve section of this manual.
E. PIPING INSTALLATION (ALL PUMPS)
1. Install flanges on fluid cylinder with special high carbon double heat-treated capscrews furnished with the pump.
2. Install suction and discharge lines to flanges.

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Assembly…
II. FLUID END (Continued)…
F. PLUNGER PACKING INSTALLATION
1. 838 PACKING
It is important that the following procedure be observed when replacing old packing to prevent rapid packing
wear. 838 packing is assembled in units consisting of a pressure ring along with a top and bottom adapter.
Each set will have two or three units. Pay attention to the arrangement of the old packing sets to ensure the
new sets are installed correctly. Another check is the units are installed so the lantern ring is positioned under
the lubrication port. If the lantern ring does not align with the lubrication port, the pump is not correctly packed.
a. Remove cradle cover and rotate pump to bring the first plunger to the forward position.
b. Back off gland nut one or two rounds.
c. If the pump has intermediate rods a back-up wrench is required. The plunger and intermediate rod separate
at the knurl area interface. Using the back-up wrench break the plunger loose and unscrew from the
intermediate rod. Remove the plunger through the fluid cylinder opening.
d. If the pump does not have an intermediate rod, use a pipe wrench on the knurled area of the plunger and
break it loose from the crosshead. Unscrew and remove through the fluid cylinder opening.
e. Remove the gland nut, old packing, and packing adapters. Note the order of the packing and adapters. Clean
the stuffing box and inspect for any damage.
f. Rotate the pump to bring the next plunger forward.
g. Repeat steps “b.” through “f.” until all the plungers and packing have been removed.
h. Check the throat bushing, lantern ring, and follower for excessive wear. These items can often be reused, but if
they are worn, replace them. Reusing worn trim will cause premature packing failure.
i. Lightly lubricate the stuffing box bore and install the throat bushing.
j. Lightly lubricate a packing unit and install each component separately insuring each component is fully seated
at the bottom of the box before installing the next component. Repeat and install the second unit. (DO NOT
GREASE).
k. Install the lantern ring. Check to ensure the lubrication port is aligned with the lantern ring. If not, too few or too
many units have been installed ahead of the lantern ring.
l. Install the last unit of packing.
m. Install the follower ring and start the gland nut. Adjust the gland nut hand tight only.
n. Lightly oil the plunger and install it through the fluid cylinder. Do not use worn plungers on new packing, as this
will shorten packing life.
o. Torque plunger and, if used, intermediate rod to 30 ft.-lbs.

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Assembly…
II. FLUID END
1. 838 PACKING (Continued)…
p. Repeat steps “h.” through “o.” until all cylinders have been repacked.
q. Tighten gland nut with the wrench provided. Pull snug by hand, but DO NOT USE A CHEATER.
r. Start the pump and operate at pressure for two to three hours while observing for excessive leakage. If
leakage is excessive, stop the pump and readjust. After the two or three hours, stop the pump and readjust.
Again, DO NOT USE A CHEATER.
s. This style packing is considered non-adjustable and should be ready to go at this point. However, it may take
as much as one or two days to fully seat. After a couple of days, stop the pump and check the packing again.
After this adjustment the pump should be ready to run without further adjustment.
FIGURE 2

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Assembly…
II. FLUID END
F. PLUNGER PACKING INSTALLATION (Continued)…
2. BRAIDED PACKING
It is important that the following procedure be observed when replacing old packing to prevent rapid packing
wear. Braided packing sets consist of braided packing rings, spacer rings, and end rings. The composition and
number of rings vary depending on the fluid compatibility and stuffing box depth.
g. Repeat steps “b.” through “f.” until all the plungers and packing have been removed.
h. Check the throat bushing and follower for excessive wear. These items can often be reused, but if they are
worn, replace them. Reusing worn trim will cause premature packing failure.
i. Ensure the stuffing box lube port is plugged or has not been drilled completely through. Braided packing does
not use a lantern ring and the port must be plugged or the packing can extrude through the port.
j. Lightly lubricate the stuffing box bore and install the throat bushing.
k. Install the first end ring into the box. Ensure it is fully seated against the bottom of the box and not cocked.
l. Install the first pressure ring into the box and ensure it is fully seated.
m. Install the spacer and ensure it is fully seated.
n. Repeat this procedure until all the packing is installed and fully seated. ENSURE THE SPLITS ON EACH
PACKING RING ARE STAGGERED FROM THE PREVIOUS RING. DO NOT ALIGN THE SPLITS.
o. Install the follower ring and loosely install the gland nut.
p. Lightly oil the plunger and install it through the fluid cylinder. Do not use worn plungers on new packing, as this
q. Torque plunger and, if used, intermediate rod to 30 ft.-lbs.

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Assembly…
II. FLUID END
2. BRAIDED PACKING (Continued)…
r. Repeat steps “h.” through “q.” until all cylinders have been repacked.
s. Tighten gland nuts finger tight. Some braided packing is very sensitive to gland tightening. Do not over tighten.
t. Start the pump and bring up to pressure. Watch the packing carefully for signs of excessive heat. If the
packing starts to smoke, back the gland off a little. Braided packing does normally drip a small amount. This is
by design and helps keep the packing from over heating.
u. Continue to slowly tighten the nut to reduce the leakage to an acceptable level. Remember this type of packing
does leak a small amount and tightening the gland until all leakage has stopped will usually result in excessive
heat and failed packing. This style packing is adjustable packing and will have to been inspected regularly to
keep the nut tight and leakage to a minimum. If the pump is allowed to operate with too loose packing, the
packing will prematurely fail and you run the risk of damaging the stuffing box.
FIGURE 3

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Assembly…
II. FLUID END
F. PLUNGER PACKING INSTALLATION (Continued)…
3. 1068-4 PACKING
1068-4 packing is spring loaded, molded V-ring style packing. It is normally used in reverse osmosis services, but
may be used in other selected applications. This is non-adjustable packing.
g. Repeat steps “b.” through “f.” until all the plungers and packing has been removed.
h. Check the throat bushing and follower for excessive wear. These items can often be reused, but if they are
worn, replace them. Reusing worn trim will cause premature packing failure.
i. Ensure the stuffing box lube port is plugged or has not been drilled completely through. 1068-4 packing does
not use a lantern ring and the port must be plugged or the packing can extrude through the port.
j. Lightly lubricate the stuffing box bore and install the throat bushing, if used.
k. Install the packing spring.
l. Lubricate and install the packing set and adapters.
m. Install the follower ring (if used) and gland nut. Do not fully tighten the gland nut at this time.
n. Lightly oil the plunger and install it through the fluid cylinder. Do not use worn plungers on new packing, as this
o. Torque plunger and, if used, intermediate rod to 30 ft.-lbs.
p. Repeat steps “h.” through “o.” until all cylinders have been repacked.

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Assembly…
II. FLUID END
3. 1068-4 PACKING (Continued)…
q. Using the standard gland wrench tighten all glands completely. The glands will pull completely up. Again, this
packing is spring-loaded and non-adjustable so once the glands are properly pulled up there is no more
adjustment.
r. Start the pump and bring up to pressure.
FIGURE 4

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PLUNGER PUMP VALVES
PAGE
I. OPERATIONAL MAINTENANCE
A. Suction and discharge ............................................................................................................................................... 36
B. Valve Covers.............................................................................................................................................................. 36
C. Valve Cover Seals ..................................................................................................................................................... 36
D. Valve Springs............................................................................................................................................................. 36
E. Valve and Seat........................................................................................................................................................... 36
II. TAPERED SEAT VALVES

A. Severe Duty Valve
1. Nomenclature........................................................................................................................................................ 37
2. Valve Removal Procedure.................................................................................................................................... 38
3. Valve Inspection Procedure ................................................................................................................................. 39
4. Valve Installation Procedure................................................................................................................................. 40
B. Disc Valve
1. Nomenclature........................................................................................................................................................ 41
4. Valve Installation Procedure................................................................................................................................. 44
C. Spherical Valve
1. Nomenclature........................................................................................................................................................ 45
4. Valve Installation Procedure............................................................................................................................47-48

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Plunger Pump Valves…

I. OPERATIONAL MAINTENANCE
A. SUCTION AND DISCHARGE
As with any plunger pump, the necessity for having an adequate suction head and proper piping design of both
suction and discharge cannot be over emphasized.
! ATTENTION !
NOISY VALVES, DUE TO IMPROPER FILLING, CAN LEAD TO SHORT LIFE AND RAPID MECHANICAL WEAR
OF THE POWER END PARTS.
B. VALVE COVERS
CAUTION
THE VALVE COVERS, AS USED WITH THE NATIONAL OILWELL VARCO PLUNGER PUMPS, MUST BE KEPT
TIGHT AT ALL TIMES. DUE TO THE DISCHARGE PRESSURE APPLYING A CONSTANT LOAD TO THE
COVERS, IT IS NOT POSSIBLE TO CHECK THEIR TIGHTNESS WITH THE PUMP RUNNING OR WITH
PRESSURE IN THE CYLINDER.
Bleed off the discharge pressure and check the tightness of the covers as outlined under the assembly procedure
for the type of cover used.
C. VALVE COVER SEALS
Tapered Seat Valves: The cover seals should be replaced as required.
D. VALVE SPRINGS
The springs used with the NATIONAL OILWELL VARCO valves are made of inconel alloy or other stainless steel.
! ATTENTION !
THESE SPRINGS SHOULD BE CHANGED APPROXIMATELY ONCE A YEAR IN ORDER TO ASSURE PROPER
VALVE ACTION AND ELIMINATE THE POSSIBILITY OF A SPRING BREAK.
E. VALVE AND SEAT
Tapered Seat Valves: There are three basic valve & seat assemblies available, depending on the type of service.
They are the severe duty (abrasion resistant) tapered seat valves, the disc tapered seat valves, and the spherical
tapered seats.

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Plunger Pump Valves (Continued)…

A. SEVERE DUTY VALVE
This section will assist in servicing the severe duty (abrasion resistant) valve in your National Oilwell multiplex pump.
1. NOMENCLATURE.
NOMENCLATURE
SPRING RETAINER
INSERT
SEAT
THREAD LOCK
VALVE BODY
SEVERE DUTY VALVE ASSEMBLY
FIGURE 5
For part numbers and pullers see the following table.
Severe Duty Valve

Discharge
Suction Valve Valve Puller
Pump Model Valve
Assembly Assembly
Assembly
2S-1H, 5S-2H, 11D-2H, 22T-2H, 32T-2H 998-016313-027 998-016313-028 002-010359-220
2S-1M&L, 5S-2M&L, 11D-2M&L, 22T-2M&L,
100SD0304 100SD0304 998-016202-091
32T-2M&L, and 31Q-2M&L

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A. SEVERE DUTY VALVE (Continued)…
2. VALVE REMOVAL PROCEDURE
a. Ensure pressure is removed from fluid end and pump is “LOCKED OUT”.
b. The discharge valve is removed through the valve cover and the suction valve is removed through the
cylinder head. Remove both covers.
c. Rotate the pump so the plunger for the cylinder you are working on is all the way back.
d. Starting with the discharge valve assembly use the cage wrench (see tools section of parts list for special
tools and numbers) and remove the valve retainer by turning the wrench counter-clockwise.
e. Remove the valve spring.
f. Remove the valve body.
g. Use the special valve puller and remove the valve seat. See Figure 6.
h. Repeat steps “c.” through “g.” for the suction valve assembly.
FIGURE 6
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3. VALVE INSPECTION PROCEDURE (See Figure 5 for part reference)
a. RETAINER
The retainer will not need to be replaced very often. It should be inspected for corrosion or to see if it has
been warped or bent. If this is the case, replace the retainer because this can cause undue wear on the
spring and improper valve action.
b. SPRING
The spring is made from inconel or other stainless steel and will work in most corrosive environments. It
should be inspected for wear and/or nicks. If such evidence is apparent, the spring should be replaced.
c. INSERT
The valve insert is made from polyurethane. A good insert is vital for good sealing in slurries or dirty fluids.
Inspect the insert for tears, nibbling, and extrusion. If the insert is worn, replace it. Generally you can
replace the insert a couple of times before having to replace the valve body.
d. THREAD LOCK
The thread lock is a nitrile rubber. It is used to lock the retainer and prevent it from backing off during pump
operation. If the thread lock is torn or damaged, replace it.
e. VALVE BODY
The valve body is heat-treated 17-4 PH stainless. Inspect the body for excessive wear, cracks, or washing.
The guides should also be inspected for proper fit in the seat and any cracks or excessive wear. Replace the
valve body when these conditions are present. If replacing the valve body, a new insert should also be used.
f. SEAT
The seat is also a heat-treated 17-4 PH stainless steel. It should be inspected for excessive wear and/or
wash on the seating surface. Also check the taper for signs of wash by or wear. If any of these conditions
exist, the seat should be replaced. Do not use an old valve body with a new seat.
With the seat out of the pump also inspect the liquid end seating area for washing or excessive wear. The
seats should fit in the liquid end with a small amount of stand off. If the liquid end seating area is washed or
there is no stand off on the seats, the liquid end will have to be repaired. This type of repair will require the
services of a machine shop.

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4. VALVE INSTALLATION PROCEDURE
a. Thoroughly clean the fluid cylinder seat area with a cleaner that will not leave an oily residue. Do not oil
the taper area of the seat or fluid cylinder seating area. This will cause the seat to “jump out” of the
bore and could cause major damage to the pump.
b. Clean the taper on the suction seat using the same precautions as with the fluid cylinder bore. The two
surfaces must be clean and dry before assembly.
c. Insert the suction seat into the fluid cylinder suction bore.
d. Using a metal plate or old worn valve body, drive the seat into place with several sharp blows from a
hammer and bar. See Figure 7.
Figure 7
e. Install the new valve body with insert.
f. Install the spring.
g. Using the cage wrench (see parts list for special tools) install the retainer cage.
h. Repeat this procedure for the discharge valve.
i. Repeat until all valve assemblies have been installed.

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II. TAPERED SEAT VALVES (Continued)…
B. DISC VALVE
1. NOMENCLATURE
NOMENCLATURE
FASTENER
RETAINER
OUTER SPRING
INNER SPRING
VALVE DISC
SEAT
Figure 8
Disc Style Valve

Discharge
Pump Model Valve
Assembly Assembly
Assembly
2S-1H, 5S-2H, 22T-2H, 32T-2H Not Available Not Available Not Available
2S-1M&L, 5S-2M&L, 11D-2M&L, 22T-2M&L, (Delrin Disc) (Delrin Disc)
998-016202-092
32T-2M&L, and 31Q-2M&L 001DP0304 001DP0304
2S-1M&L, 5S-2M&L, 11D-2M&L, 22T-2M&L, (Titanium Disc) (Titanium Disc)
998-016202-092
32T-2M&L, and 31Q-2M&L 001TP0304 001TP0304

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B. DISC VALVE (Continued)…
a. Ensure pressure is removed from the fluid end and pump is “Locked out”.
d. Starting with the discharge valve assembly remove the socket head capscrew holding the retainer in place.
e. Remove the retainer and valve springs.
f. Remove the valve disc.
g. Use the special valve puller and remove the seat. See Figure 9.
h. Repeat steps “c.” through “g.” for the suction valve assembly.
Figure 9

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B. DISC VALVE (Continued)…
3. VALVE INSPECTION PROCEDURE (SEE FIGURE 8 FOR PART REFERENCE)
a. FASTENER
The fastener has a nylon lock tab or a lock patch. Inspect the fastener for corrosion, damaged threads,
straightness, and condition of the locking tab. If the fastener is damaged, replace it. The locking tab can be
used more than once. However, if the resistance when the tab engages the thread is minimal, replace it.
b. RETAINER
springs and improper valve action.
c. SPRINGS
The springs are made from inconel or other stainless steel and will work in most corrosive environments. It
should be inspected for wear and/or nicks. If such evidence is apparent, the springs should be replaced.
d. VALVE DISC
The valve disc is either Delrin or Titanium. Inspect the disc for excessive wear, cracks, or washing. If any
of these conditions exist, replace the disc.
e. SEAT
The seat should be inspected for excessive wear and/or wash on the seating surface. Also check the webs
for any cracks and the thread for any tears or damaged threads. Check the taper for any signs of wash.
Replace the seat if these conditions exist.
a. Thoroughly clean the fluid cylinder seat area with a cleaner that will not leave an oily residue. Do not oil
the taper area of the seat or fluid cylinder seating area. This will cause the seat to “jump out” of the
bore and could cause major damage to the pump.
c. Insert the suction seat into the fluid cylinder suction bore.
d. Using a metal plate or old worn valve body, drive the seat into place with several sharp blows from a
hammer and bar. See Figure 10.

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B. DISC VALVE
4. VALVE INSTALLATION PROCEDURE (Continued)…
FIGURE 10
e. Install the valve disc.
f. Install the valve springs.
g. Install the retainer.
h. With one hand push the retainer down to compress the springs and start the neck of the retainer through the
valve disc. Hand start the fastener.
i. Tighten the fastener to 12 to 15 ft.-lbs while ensuring the retainer pulls down against the seat and does not
clamp the disc down. The disc has to move up and down on the retainer neck.
j. Repeat this procedure for the discharge valve.
k. Repeat for the remaining cylinders.

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II. TAPERED SEAT VALVES (Continued)…
C. SPHERICAL VALVE
1. NOMENCLATURE
NOMENCLATURE
RETAINER SPRING
VALVE BODY
WAVE RING
SEAT
SPHERICAL VALVE ASSEMBLY

Figure 11
Spherical Valve
Discharge
Pump Model Valve
Assembly Assembly
Assembly
2S-1H, 5S-2H, 22T-2H, 32T-2H Not Available Not Available Not Available
2S-1M&L, 5S-2M&L, 11D-2M&L, 22T-2M&L,
179150025W 179150025W 181259201
32T-2M&L, and 31Q-2M&L

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C. SPHERICAL VALVES AND SEATS (Continued)…
a. Ensure pressure is removed from fluid end and pump is “LOCKED OUT”.
d. Remove the spring retainer by pressing downward on the puller head and turn counter clockwise about 1/8
of a turn or until retainer stops. Remove the retainer with the retriever. See Figure 13.
e. Remove spring(s) and valve with the retriever. See Figure 15.
f. Remove seat by placing the puller head through the seat opening and engage lugs to the underside of the
seat. Pull seat or bump seat loose and remove. See Figure 15.
g. Repeat steps “c.” through “f.” for the suction valve assembly.
3. VALVE INSPECTION PROCEDURE (SEE FIGURE 11 FOR PART REFERENCE)
a. RETAINER
springs and improper valve action.
b. SPRINGS
The springs are made from inconel or other stainless steel and will work in most corrosive environments. It
should be inspected for wear and/or nicks. If such evidence is apparent, the spring should be replaced.
c. VALVE BODY
The valve body is a stainless steel spherical disc. Inspect the valve for excessive wear, cracks, or washing.
If any of these conditions exist, replace the valve.
d. SEAT
The seat is stainless steel and should be inspected for excessive wear and/or wash on the seating surface.
Also check the lugs, which engage the retainer for any damage. Check the taper for any signs of wash.
Replace if these conditions exist.
e. WAVE RING
The wave rings protects the valve integrity and is a safety device to prevent the cage from coming loose in
the rare event a spring breaks. Check the wave ring for cracks or damage. Replace if necessary.
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a. Thoroughly clean the cylinder taper with a cleaner that will not leave an oily residue. Do not oil the taper
area of the seat or fluid cylinder seating area. This will cause the seat to “jump out”.
c. Inspect for corrosion or damaged areas. Repair or replace as required.
d. Place seat in the suction bore making certain it is straight.
e. With a bar and a driver tap seat in place with two or three strokes. NOTE: Seat does not have to be
completely seated. Pump start-up pressure will drive seat home. See Figure 16.
f. Install valve, spring(s), and spring retainer. See Figure 17.

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Figure 12 Figure 13 Figure 14 Figure 15
Figure 16 Figure 17
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P-55U LUBRICATOR
I. PUMP OPERATING INSTRUCTIONS
A. Operating Instructions.................................................................................................................................. 50
1. Box Suction Pumps................................................................................................................................. 50
2. Flow Rate Adjustment............................................................................................................................. 50
3. Sight Glass.............................................................................................................................................. 50
4. Overfilling of Sight Glass......................................................................................................................... 50
5. Reservoir Oil Level.................................................................................................................................. 50
6. Pump Displacement................................................................................................................................ 50
STORAGE OF PUMPS
I. GENERAL
A. General........................................................................................................................................................ 51
B. Recommended Protection and Initial Storage............................................................................................. 51
C. Six Month Servicing .................................................................................................................................... 52
D. Pre-Installation Check After Storage........................................................................................................... 52
OWNERS RECORD ............................................................................................................................ 53

TYPICAL WATERFLOOD PUMP INSTALLATION SUCTION and
DISCHARGE PIPING ARRANGEMENT .......................................................................... 54
VISCOSITY EQUIVALENTS ....................................................................................................... 55

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P-55U Pump…
A. OPERATING INSTRUCTIONS
4. OVERFILLING OF SIGHT GLASS
1. BOX SUCTION PUMPS (VACUUM FEED)
In a vacuum type sight feed, it is not uncommon to
see a reverse action whereas sight glass fills with oil and
• Fill reservoir with oil. the drops cannot be observed. Overfilling is caused by
oil absorbing air in the sight glass and normally does not
• Loosen union nut on pump outlet.
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
• Remove the vent screw and fill the sight glass with oil. drip tube can be observed in the sight glass. If overfilling
Prime by manually pumping flushing unit until air free oil continues, it may be caused by plunger wear and oil
is observed from the drip tube and oil level drops in the slippage is being drawn back to sight glass. If this is the
sight glass. problem, the feed setting in drops per stroke will then
automatically be reduced by the amount of slippage.
• Replace vent screw and tighten union nut. 5. RESERVOIR OIL LEVEL (LOSS OF PRIME)
• Maintain oil level in sight glass below the drip tube so If reservoir runs low on oil (at a point below the
drops can be observed. suction inlet of the pump) it may be necessary to prime
individual pumps after filling, using procedure listed
2. FLOW RATE ADJUSTMENT above.
•
6. PUMP DISPLACEMENT
Loosen locknut on flushing unit.
Maximum output (per stroke):
• Turn flushing unit counter-clockwise to increase flow.
1/4 Plunger = .018 Cubic Inches
3/8 Plunger = .038 Cubic Inches
• Turn flushing unit clockwise to decrease flow.
The cubic volume for a pint of oil is 28.9 cubic inches
• Tighten locknut when desired flow rate is achieved. and average drop size is .002 cubic inches.
3. SIGHT GLASS
Vent Screw Pump Outlet, 1/8” NPT
In a vacuum type sight feed, it is not uncommon for
oil level in the sight glass to drop during operation.
Sight Glass
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 Union Nut
excessive, it can eventually air lock the pump. Flushing Unit
For this reason it is recommended that an oil level in

the sight glass be maintained. Lock Nut
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.
Suction Inlet
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Storage of Pumps…
I. GENERAL
All machinery units require protection from corrosion erosion, natural attrition which causes deterioration of the
surface as well as the working parts. Generally, units in operation are frequently inspected, cleaned, painted and
lubricated while idle units are often more or less neglected. Any degree of neglect is costly, especially if continued over
a sufficient period of time to make restoration of the equipment impossible. It is recommended that preventive measures
of protection be established and the following will guide you in the minimum requirement.
A. GENERAL
Preferably, units should be stored in clean, climatically controlled buildings. This would require the minimum
inspection, but, since storage in older environments is sometimes necessary, more frequent inspections and additional
protection is necessary. The schedule for inspection and protection can be determined only at the point of storage. A
protection and storage log is recommended. Tropical areas require the maximum protection; arid regions require the
least amount of protection. The frequency of inspection is determined after noting the rate of deterioration. Take
positive action immediately when corrosion/erosion appears, do not wait until large areas are covered because usually
the larger the area, the deeper the penetration.
B. RECOMMENDED PROTECTION INITIAL STORAGE
1. Drain all oil and thoroughly clean inside of Power Frame.
2. Coat pinion shaft oil seals with grease.
3. Remove breathers for later installation on pump. Seal all breather holes with greased solid pipe plugs. Remove
extension rods and diaphragm sealing housing; be sure to protect the rods and housings, storing them
separately for later installation on the pump. Seal diaphragms with wooden covers. “Mate” the wood cover and
diaphragm faces together, thoroughly coating with Rust Veto 342 or its equivalent.
4. Spray two gallons of Shell VSI 100 vapor phase inhibitor or equivalent into power end of pump.
5. Remove valves and valve springs. Clean and wrap in corrosion inhibiting paper. Remove liners and pistons.
Clean and wrap in corrosion inhibiting paper. Clean and dry fluid end bores and thoroughly coat all internal
surfaces with Tectyl 506 or equivalent.
6. Thoroughly coat all threads and end of valve cover and screw into fluid end.
7. Protect all external machine surfaces using Rust Veto 342 or equivalent including pump pads.
8. Inspect complete pump and record all details on the Protection and Storage Log.

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Storage of Pumps…
I. GENERAL (Continued)
C. SIX MONTH SERVICING
1. Rotate pump.
2. Renew internal rust inhibitors to specifications and quantities previously stated under the “Initial Storage”
section.
3. Before replacing top and side covers, inspect for any internal corrosion.
4. Inspect for soundness of external protection, i.e., rust preventative and paint. Renew as necessary.
5. Enter and record all details on the “Protection and Storage Log”.
D. PRE-INSTALLATION CHECK AFTER STORAGE
1. Repeat six month servicing procedure as stated above.
2. Ensure all necessary parts are complete and in a satisfactory condition for installation on pump.
3. Enter all records and close out the “Protection and Storage Log”.
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Owners Record…
NAME _______________________________________________________________________________________
LOCATION ___________________________________________________________________________________
DATE OF DELIVERY ________________________________ DATE PLACED IN OPERATION _______________
PUMP MODEL ________________________________________________________________________________
PUMP SIZE ________________________________________ SERIAL NO. _______________________________
PRIME MOVER _____________________________________ SERIAL NO. _______________________________
GEAR UNIT ________________________________________ SERIAL NO. _______________________________
DRIVE:
DRIVE SHEAVE P.D._____________ DRIVEN SHEAVE P.D. ________________ NO. OF GROOVES ________
BELT LENGTH__________________ DRIVE SPROCKET __________________ CHAIN SIZE ______________
CHAIN LENGTH_________________ COUPLING (MAKE) __________________ COUPLING SIZE __________
PRESSURE____________ VOLUME ________________ PUMP SPEED ___________ DRIVE SPEED _________
PLUNGERS___________________________________________________________________________________
PACKING ____________________________________________________________________________________
PISTONS_____________________________________________________________________________________
LINERS ______________________________________________________________________________________
VALVES______________________________________________________________________________________
SEATS_______________________________________________________________________________________
LUBRICANTS:
CRANK CASE _______________________________________________________________________________
FLUSHING SYSTEM __________________________________________________________________________
GEAR UNIT _________________________________________________________________________________
LUBRICATOR _______________________________________________________________________________
PRIME MOVER ______________________________________________________________________________
COUPLING__________________________________________________________________________________
NOTES ______________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
All of the above entries are not applicable to a specific unit, therefore, completion of this form must be confined within
the limits of each pump and the specified optional accessory equipment.

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Typical Waterflood Pump Installation Suction and Discharge Piping

Arrangement…
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Viscosity Equivalents…

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Notes and Comments:
56
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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/
National Oilwell Varco is a leading © Copyright 1999 by National Oilwell, L.P. All Rights
Sales/Technical Information: Reserved. NATIONAL OILWELL, NATIONAL, and
USA Tollfree: 1 (800) 324-4706 manufacturer of reciprocating plunger OILWELL are registered trademarks of NATIONAL
pumps, Mission Fluid King centrifugal OILWELL, L.P. Houston, Texas, USA. All other
pumps, and fluid end replacement parts. trademarks used are registered to their respective
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companies. The information and data in this
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2S 5S 11D 22T 32T 31Q Multiplex Plunger Pumps Manual

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Multiplex Plunger

22T-2 Covering the

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THE PRESSURE RELIEF VALVE:

SUGGESTED SET PRESSURES FOR THE PUMP RELIEF VALVES:

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! CAUTION! CAUTION! CAUTION!

! WARNING! WARNING! WARNING!

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! 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.

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Plunger Pump Nomenclature Example….

STROKE LENGTH (IN.)

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II. TROUBLE SHOOTING GUIDE...................................................................................................................... 15-16

OVERHAUL AND REPAIR

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Table of Contents (Continued)…

II. FLUID END

II. FLUID END

VALVE SECTION ............................................................................................................................. 35-48

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5. Pulsation dampening devices are strongly recommended.

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B. DISCHARGE LINE (Continued…)

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F. PLUNGER PACKING LUBRICATION

G. SUCTION PULSATION DAMPENERS

1. Low Pressure - Plastic Body

c. Tighten capscrews with 10 to 12ft-lbs. of torque.

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G. SUCTION PULSATION DAMPENERS (Continued)…

2. High Pressure - Aluminum Body

c. The following procedures should be used to service this dampener:

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U.S. UNITS OF MEASURE

Crankcase Capacity - Quarts: 2S-1 – 2 5S-2 – 2 11D-2 – 3-1/2

METRIC UNITS OF MEASURE

Crankcase Capacity - Liters: 2S-1 – 1.9 5S-2 – 1.9 11D-2 – 3.3

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

3. Do not over-speed 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.

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3. Check lubricator for proper level and operation.

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

5. Check stuffing box adjusting nuts for tightness.

6. Drain plunger leakage sump tanks if required.

10. Check all seals for leakage.