SPM®

Well Service Pumps & Flow Control Products

QWS2500 SD Grooved and Grooveless Fluid End

Operation Instruction and Service Manual

Document P/N: 2P136539

Release Date: 12/27/2011
Revision: E

Copyright © 2014, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information
in this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any
purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON,
SAFETY HAMMER, SUR-DROP, DESTINY, STAMPEDE, VERIBAND, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow
Control, Inc.. WEIR is a trademark and/or registered trademark of Weir Engineering Services Limited. Certain features of some of the products disclosed in
this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..
Document P/N: 2P136539
Release Date: 12/27/2011
Revision: E

THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL

GENERAL INFORMATION

INSTALLATION AND OPERATION

MAINTENANCE AND REPAIR

SALES AND SUPPORT

NOTE

CAUTION

WARNING/ DANGER

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Document P/N: 2P136539
Release Date: 12/27/2011
Revision: E

SPM® PRODUCT SAFETY GUIDE FOR WELL SERVICE PUMPS

Most SPM® products generate control or direct pressurized fluids; therefore, it is critical that those who work
with these products be thoroughly trained in their proper application and safe handling. It is also critical that
these products be used and maintained properly!

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “WELL SERVICE PLUNGER PUMP SERVICE MANUAL” THOROUGHLY. TRAINING
IN THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS AND MAINTENANCE PERSONNEL.
FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE, PROPERTY DAMAGE
OR DAMAGE TO THE ENVIRONMENT.

WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER PRESSURE

CAN CAUSE SERIOUS INJURY OR DEATH.

The following information is given in good faith and should aid in the safe use of your SPM® products. This
information is not meant to replace existing Company's safety policies or practices.

Hot Surfaces: A SPM® well service pump is capable of pumping fluids with temperatures up to 65°C/150°F with
normal trim. The power end of the pump can be operated at temperatures up to 79°C/175°F. It is the
responsibility of the packager to provide adequate guarding around the fluid end as well as the inlet and
discharge piping to protect against burn injury.

A SPM® well service pump operates at very high pressure and features some external moving parts. It is the
customer's responsibility to provide adequate warning and protection for personnel for when the unit is
operated.

All images and drawings shown in this document are for representation and illustration purposes only. They
don’t reflect the actual part/component.

The bill of materials and part numbers in this document can change without notification. For details contact
Weir Oil & Gas.

Personal Responsibilities:

1. When working on the pump, safety glasses, approved safety shoes and hard hat must be worn. Fall
prevention and protection should be in place when working on the pump in raised areas. Surfaces can
become slippery when servicing the pump.
2.
3. Personnel should only hammer on the SPM® hammer wrench provided and never directly on the pump
itself. Fractures can occur from repeated misuse. Only soft-type hammers should be used.

4. Personnel should never hammer on or any pump components when pressure is present. Hammering on
any part or component may cause foreign material or steel pieces to become airborne.

5. When servicing the pump, do not manually lift any part in excess of 40 lbs. A lift device must be used
in these cases. For parts weighting 40 lbs. or less, proper leg type lifts are essential. Do not lift with a
back type lift.

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6. It is a personal responsibility to use the proper tool when servicing the pump. Any special tools required
are furnished with the pump when new, and should be kept with the pump for its routine maintenance.
It is a personal responsibility to be knowledgeable and trained in the use and proper handling of these
tools for all maintenance of the pump. A pump is made up of internal and external moving parts. All
personnel should be located away from the pump while in operation. Only trained personnel should be
around the pump, especially during service or operation.

On Location:

1. Each pump is clearly marked with a maximum pressure and temperature rating. This pressure must not
be exceeded or SERIOUS INJURY OR DEATH CAN OCCUR.

2. Each pump is clearly marked with a maximum horsepower rating. This horsepower rating should not
be exceeded or mechanical damage can occur, leading to SERIOUS INJURY OR DEATH.

3. The pump's discharge connections should be properly cleaned and lightly oiled before the downstream
piping is attached. Any worn, damaged or missing seals should be replaced before engaging the
pump's drive.

4. The pump's suction connections should be properly cleaned and lightly oiled before the supercharge
hoses are attached. Any worn, damaged or missing seals should be replaced prior to pumping. Leaking
connections can cause pump cavitation leading to equipment failure and subsequent INJURY OR
DEATH.

5. Any fluid cylinder which has been pressured beyond its specified working pressure should be returned
to Weir Oil & Gas for disassembly, inspection and recertification.

6. Welding, brazing or heating any part of the pump, with the exception of driveline companion flanges, is
prohibited. If accessories must be attached, consult Weir Oil & Gas factory prior to installation.

7. The SPM® pump suction supply flow and pressure minimums in the pump service manual must be
maintained or equipment damage will occur and can lead to SERIOUS INJURY OR DEATH.

8. A complete visual inspection of the pump's power end and fluid end must be made prior to each use.
Any leaking seals, broken bolts, leaking hoses or improperly tightened parts must be remedied prior to
rotating the pump.

9. Any oil and other contaminants from pump should be contained during operation and throughout the
maintenance process. Improper containment can lead to serious injury, equipment damage, property
damage, or damage to the environment.

10. If a pump is used in a place where permanent piping is to be attached, frame flexing or structure
movements must be considered. Do not place the discharge or suction connections in a bind. Inspect
all components of such piping structure, including any valves, every 90 days for wash, erosion,
corrosion, etc. Replace if worn. For mobile mounted units; discharge line swivels are required.

11. SPM® well service pumps are to be installed and operated in a horizontal position only, as shown in the
pump's service manual. Operation in an extreme inclined position could cause equipment failure,
leading to injuries due to improper oil flow and/or improperly sealing valves.

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12. Any repairs or service (even routine maintenance) performed on the pump must be performed by a
trained service technician who is qualified to work on high pressure reciprocating plunger pumps. All
such service and repairs must be supervised by qualified management personnel or returned to Weir Oil
& Gas for service. Only SPM® replacement parts should be utilized. Failure to do so may result in loss of
warranty as well as SERIOUS INJURY OR DEATH. Weir Oil & Gas provides a Pump Maintenance
Mechanic Training School to qualify pump service mechanics.

13. SPM® well service pumps should never be used to pump gaseous, explosive or uninhibited corrosive
fluids. These may result in equipment failure, leading to INJURY OR DEATH.

14. Never place hands in area of reciprocating pony rod or plunger path. If work must be done in this area,
make sure pump is disengaged from driver and isolated from suction and discharge pressure prior to
initiating activity (locked out and tagged out).

Special Precautions:

1. The modifications to or unauthorized repair of any part of an SPM® pump, or use of components not
qualified by SPM®, can lead to pump damage or failure and SERIOUS INJURY OR DEATH.

2. The pump's fluid end and related piping must always be flushed with clean water after every job. If
freezing temperatures are anticipated the fluid cylinder must be completely drained of any fluid. Failure
to do this may result in fluid cylinder damage from fluids which have hardened or frozen.

3. All SPM® threaded components are right hand threaded unless specifically designated otherwise. Any
turning counterclockwise will unscrew the assembly. Always make sure any threaded component is
made up properly with the proper torque.

4. All products should be properly cleaned, greased or oiled after each use and inspected prior to each use.
Do not put oil on the valve seat or fluid end valve seat tapered area.

5. Pressure seal (line pipe) threads are not recommended for pulsating service above 10,000 psi or where
side loading or erosion are suspected. Non-pressure seal (round tubing) threads or straight integral
connections are recommended under these conditions. In order to achieve the recommended Non-
Shock Cold Working Pressure, power-tight make-up is required on threaded connections. Consult the
factory for any usage other than normal constant flow working conditions. Integral connections are
recommended in lieu of pipe threaded connections for all pump applications.

6. Each integral union connection is clearly marked with a pressure code (i.e. “1502”, 15,000 psi). This
pressure must not be exceeded. This code should also be used with mating unions. Improper mating
can result in failures. All integral union connections used must match (according to size, pressure
rating, etc.). These connections must also match the service of the designated string they are installed
in.

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Inspection & Testing:

1. Each pump, its drive system, and its fluid piping should be visually checked each time before operating.
All worn, damaged or missing parts should be remedied before starting the pump.

2. All fluid cylinder mounting nuts must be checked routinely with a certified torque wrench. Loose fluid
cylinder mounting nuts can cause the fluid end to separate from the power end resulting in SERIOUS
INJURY OR DEATH.

3. All studs and stay rods require tightening to the proper torque. Without proper torque, the fluid end
will "breathe" or flex against the power end resulting in stud failure, stay rod failure and/or even
premature fatigue failure in the power or fluid end. Consult Weir Oil & Gas for torque information (see
assembly drawings for torque values).

4. All covers must be tight and properly torqued. Otherwise, premature fatigue and possible fluid end or
component failure can result.

5. All fluid ends must be disassembled and dimensionally inspected routinely. Any fluid cylinder or
discharge flanges which exhibits any loss in wall thickness due to washing or corrosion pitting in any
area must be returned to Weir Oil & Gas for repair and recertification prior to operating again.

6. All fluid cylinders in operation must be disassembled and inspected for cracks. Fluid cylinder inspection
should occur on a monthly basis or every 100 hours of operation. The operation of any pump with even
small surface cracks in any area of the fluid cylinder can result in equipment failure and SERIOUS INJURY
OR DEATH.

7. All fluid cylinders should be hydrostatically tested at least twice each year by a qualified technician.
Prior to any pressure testing, all air must be evacuated from the system. Failure to do so could result in
PERSONAL INJURY OR DEATH. The maximum test pressure must not exceed the equipment's rated
working pressure. The hydrostatic pressure test must be followed with an ultraviolet light/magnetic
particle inspection of the internal bores prior to reinstalling and operating under pressure.

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Revision: E

TABLE OF CONTENTS

SECTION I: GENERAL INFORMATION ............................................................................................................. 8

USEFUL PUMP DATA FORMULAS: ........................................................................................................................ 8
SHIPPING AND STORAGE: ................................................................................................................................ 10
SECTION II: INSTALLATION AND OPERATION .............................................................................................. 11
SPM® QWS2500 SD PUMP DESCRIPTION: ....................................................................................................... 11
INSTALLATION HIGHLIGHTS:............................................................................................................................. 13
LIFTING REQUIREMENTS: ................................................................................................................................. 14
PLUNGER LUBE SYSTEM REQUIREMENTS:............................................................................................................. 14
RECOMMENDED PLUNGER LUBE OILS: ............................................................................................................... 16
RECOMMENDED PLUNGER GREASE LUBE SYSTEM: ................................................................................................ 18
PLUNGER LUBE CIRCUIT DIAGRAM:.................................................................................................................... 19
SUPERCHARGING SYSTEM REQUIREMENTS: .......................................................................................................... 20
SUPERCHARGING SYSTEM OPERATIONAL PARAMETERS: .......................................................................................... 25
RECOMMENDED PRACTICE FOR PUMP PACKING: .................................................................................................. 26
TACH DRIVE/RATE METER CALIBRATION SPECIFICATIONS: ...................................................................................... 30
STARTUP AND BREAK-IN PROCEDURE: ................................................................................................................ 31
SECTION III: MAINTENANCE AND REPAIR .................................................................................................... 35
ROUTINE PREVENTATIVE MAINTENANCE: ............................................................................................................ 35
TROUBLESHOOTING GUIDE: ............................................................................................................................. 38
SPM® QWS2500 SD FLUID END REPAIR PROCEDURES: ....................................................................................... 40
SUCTION VALVE STOP INSTALLATION FOR GROOVELESS FLUID ENDS: ...................................................................... 44
SUCTION VALVE STOP INSTALLATION FOR GROOVED FLUID ENDS: .......................................................................... 47
SECTION IV: PUMP PARTS ............................................................................................................................ 49
GENERAL INFORMATION:................................................................................................................................. 49
WEIR OIL & GAS LOCATIONS:.......................................................................................................................... 50
FLUID END DRAWINGS:................................................................................................................................... 51

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Document P/N: 2P136539
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Revision: E

SECTION I: General Information

Useful Pump Data Formulas:
Definition of Symbols Used:

A - Area (sq. in.)

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

Pump Data Formulas:

 To calculate the HHP output when the volume and pressure are known:

GPM x PSI = HHP

1714

 To calculate the BHP input required when the volume, pressure, and mechanical efficiency are known:

GPM x PSI = BHP

(1714 x ME)

 To calculate the maximum possible pressure when the BHP, flow, and ME are known:

BHP x (1714 x ME) = PSI

GPM

 To calculate the maximum possible flow when the BHP, PSI, and ME are known:

BHP x (1714 x ME) = GPM

PSI

 To calculate rod load when the plunger diameter and pressure are known:

PD x PD x .7854 x PSI = RL

 To calculate the maximum possible pressure at a given rod load when the RL rating and plunger
diameter are known:

RL = PSI
PD x PD x .7854
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 To calculate the flow in gal/rev or GPM when the plunger diameter, stroke length, and number of
cylinders is known:

PD x PD x .7854 x SL x NC = GPR
231

GPR x RPM = GPM

 To calculate the fluid flow velocity through a pipe or hose when the GPM and pipe size are known:

Pipe I.D. x Pipe I.D. x .7854 = Internal Area = A

GPM x .3208 = Flow Velocity

A

 To calculate the size pipe of hose required to maintain a specified flow velocity when the GPM and
desired flow velocity are known:

GPM x .3208 = Internal Area Required

FV

 To calculate the maximum allowable GPM through a specified hose or pipe at a specified flow velocity
when the internal area of the pipe and the desired flow velocity are known:

FV x A = Max GPM
.3208

 To calculate pinion shaft or driveline torque when the input BHP and pinion shaft RPM are known:

BHP x 5252 = Torque

Pinion Shaft RPM

Conversion Factors:

Multiply: By: To Obtain:

Barrels (U.S.) 42 Gallons (U.S.)
Gallons (U.S.) .023809 Barrels (U.S.)
Gallons (U.S.) 231 Cubic Inches
Cubic Inches .004329 Gallons (U.S.)
Cu. Ft./Sec. 448.831 GPM
GPM .002228 Cu. Ft./Sec.
Head Feet (water) .4331 PSI
PSI 2.309 Head Feet (water)
Kilowatts 1.341 Horsepower
Horsepower .7457 Kilowatts

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Shipping and Storage:

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE, OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGLY. TRAINING
WITH THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND MAINTENANCE
PERSONNEL. FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE,
PROPERTY DAMAGE, OR DAMAGE TO THE ENVIRONMENT.

All SPM® pumps are shipped dry and must be flushed and filled with the proper lubricant before operating
(refer to Installation and Operation Section). Pumps may be flushed with diesel or light oil. When pumps are
shipped by ocean cargo, care should be taken to crate the pump in a watertight container and ship below deck
to prevent salt-water contamination.

New pumps are not prepared for long periods of storage and should be put in service as soon as possible. To
prepare a pump for storage after prior use, clean the fluid end and flush it with good rust preventive. Plug all
fluid end discharge and suction openings. Drain oil from power end, thoroughly clean and flush with a good
rust preventive, which will not clog oil passages. Remove crankcase breather and plug all openings. Coat the
pinion extensions and pony rods with a heavy rust preventive. Store pump inside in a warm, dry place.

CAUTION: PUMPS THAT HAVE SAT IDLE FOR ANY APPRECIABLE PERIOD OF TIME (TWO WEEKS OR
MORE) MUST HAVE THE PLUNGERS AND VALVES REMOVED, COATED WITH A LIGHT LUBRICANT AND
REINSTALLED PRIOR TO OPERATING. THE ELASTOMERIC PLUNGER PACKING AND VALVE INSERTS WILL
STICK TO THE MATCHING METAL PARTS AND BECOME DAMAGED UPON STARTUP IF NOT
DISASSEMBLED AND LUBRICATED FIRST.

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SECTION II: Installation and Operation

SPM® QWS2500 SD Pump Description:

The SPM® QWS2500 SD is a reciprocating, positive displacement; horizontal single-acting, quintuplex plunger
pump which is rated at 2500 Brake Horsepower, input maximum. The SPM® QWS2500 SD is designed for
intermittent duty well service applications such as acidizing, fracturing, well killing, etc.

The SPM® QWS2500 SD Pump consists of a Power End Assembly and a Fluid End Assembly. Nine different fluid
cylinders are available to accommodate nine different plunger sizes for a variety of pressures and volumes.

Optional packing assemblies, valve assemblies, discharge flanges, suction manifolds, etc. are available for a
wide variety of unitization arrangements, for the pumping of various specific fluids, and for service in a wide
range of ambient conditions. The weight of the pump will vary slightly depending on plunger size and other
options, but will not vary more than plus or minus 5% of the advertised weight.

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The SPM® QWS2500 SD fluid end design and construction details are as follows:

Fluid Cylinder
Durable low maintenance “Valve Over Valve” monoblock design. Precision machined from high strength heat-
treated alloy steel forging (for sizes 3 ¾” thru 6”) and steel casting (for sizes 6 ½” thru 6 ¾”).

Plungers
“Quick Disconnect” clamp disconnection. Machined from steel w/precision ground hard overlay (60 Rc) acid
resistant packing surface.

Plunger Packing
“Self-adjusting” type packing assemblies. Precision molded fiber reinforced V-type pressure rings. Supported
by precision-machined bronze adapter rings. Various compositions available for all common well service fluid
media such as hydrocarbons, toluene, etc. and for a wide range of ambient temperatures.

Valve Covers
Threaded “knockout” type valve covers for ease of maintenance. Available with center discharge gauge
connection.

Valve Assemblies
Wing guided well service type valves w/replaceable urethane or neoprene inserts. Tapered well service type
valve seats w/auxiliary seal ring.

Valve Springs
Long lasting coil springs engineered for a wide range of well service applications. Designed for spring rates,
installed spring loads, and valve cracking pressures unique to well service pumps.

Suction Valve Keepers

Low fluid restriction type keepers located out of the high stress plane of the fluid cylinder.

Discharge Flanges
Dual (RH & LH) outlet design. Offset port design. Replaceable type discharge flanges precision machined from
heat-treated alloy steel. Available in male or female with a variety of common well service connections such as
LPT and integral hammer union male or female subs (fig. 602, 1002, 1502, 2002, etc.)

Suction Manifold
Dual inlet (RH & LH) design. Replaceable type manifold fabricated from steel, precision machined, and
pressure tested. “Quick Disconnect” victaulic “ES” connections on both ends. Available w/cylinder drains
(suction valve lifters).

Fluid Seals
Precision molded high-pressure acid resistant fluid seals made from a superior Polyurethane/Molydisulfide seal
compound.

Packing Lubrication
Equipped for a pressurized oil based packing lube system.

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Installation Highlights:
The proper installation of your SPM well service pump is a must in obtaining long life and trouble free service.
Particular attention must be given to the following items:

A. Power Source:
The prime mover should be rated at no more than 2700 BHP intermittent service in order to avoid
overpowering the pump.

B. Drivetrain:
The drivetrain which connects the pump to the engine should include a transmission (7 speed or more)
and a mechanical driveline with universal joints and a slip joint in order to fully utilize the pump's wide
range of pressure and flow capabilities.

A powershift type transmission with integral torque converter and automatic lock-up clutch will provide
the most trouble-free means of shifting under pressure. When using any transmission with a “high gear”
or “overdrive” ratio greater than 1.0:1, the “overdrive” gear range must be blocked out in order to avoid
overspeeding the pump. Extreme caution should be exercised in order to avoid over-pressuring the
pump when operating in low gear or converter mode.

The mechanical driveline should have a “Diesel Engine Use” torque rating of 20,000 ft. lbs. (96,000 ft.
lbs. Short Duration) and should have no less than 1” slip capacity. The manufacturer's recommendations
for maximum installed angle, maximum RPM, etc. must not be exceeded.

C. Power End Mounting:

The pump must be securely bolted to the skid or vehicle at all four power end mounting hold locations
(Refer to pump installation drawing).

D. Power End Lubrication:

SPM well service plunger pumps are shipped dry, do not include an integral oil pump, and are designed
for a pressure lubricated dry sump system. An auxiliary oil reservoir and engine driven oil pump must be
provided for proper lubrication. More information pertaining to the power end lube system and power
end lube oils is included in this manual.

E. Plunger Lubrication:
SPM well service plunger pumps require a force fed oil base plunger lube system. More information
pertaining to the plunger lube system and plunger lube oils is included in this manual.

F. Supercharging System:
SPM® well service plunger pumps require the use of a centrifugal slurry pump supercharging system to
avoid cavitation at the higher pump speeds. More information pertaining to the supercharging
requirements is included in this manual.

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Lifting Requirements:
The SPM® QWS2500 SD fluid end weighs approximately 4,804 lbs. (2179 kg) dry, fully assembled with a
standard fluid end and suction manifold.

CAUTION: DO NOT MOUNT THE PUMP ON AN INCLINE OR VERTICALLY.

WARNING: LIFTING THE SPM® QWS2500 SD PUMP OR QWS2500 SD FLUID END ASSEMBLY WITHOUT
USING EQUIPMENT RATED FOR THIS LOAD CAN CAUSE EQUIPMENT DAMAGE, PERSONAL INJURY OR
DEATH.

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE OR MAINTAIN THIS SPM® PUMP WITHOUT
READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGHLY. TRAINING IN
THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS AND MAINTENANCE PERSONNEL.
FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE, PROPERTY DAMAGE
OR DAMAGE TO THE ENVIRONMENT.

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Plunger Lube System Requirements:

SPM® well service plunger pumps are designed for packing lubrication with oil rather than grease.
Exceptionally long packing life can be expected providing proper lubrication is supplied to the plunger packing
lube port above each stuffing box. Weir Oil & Gas recommends a low-pressure air-operated type system for
plunger lubrication. Mechanically driven plunger lubricators are not recommended due to the well service
pump’s extreme variations in pump speeds. A properly designed packing lube system will meet the following
specifications:
1. Oil Reservoir:
 Should be a minimum of 15-gallon capacity.
 Should be equipped for the vertical installation of an air-operated pump.
 Should be equipped with a sight glass or dipstick.
 Should be equipped with a breather/filler cap that has a built-in strainer to prevent trash from
entering the reservoir.
2. Air Operated Lubricant Pump:
 Vertical air operated 12 oz. per minute / 150 PSI / 40:1 ratio lubricant pump.
 Must be equipped with a 1/4” adjustable air pressure regulator in order to adjust the pump
speed and packing lubricant flow rate.
 Should be installed so that the bottom of the pump is no closer than 1” to the bottom of the
reservoir.
3. Packing Lubricant Flow Lines:
 Should be 1/4” I.D./1250 PSI minimum/fiber or wire reinforced hose to prevent crimping.
 Should be a common line from the lubricant pump to the plunger pump at which point it will
branch off to each individual packing lube port.
4. Flow Control Needle Valves:
 Should be a 1/4” needle valve which can be locked at any given setting after adjustment.
 Must be installed in each lubricant flow line which leads to the individual packing lube ports in
the plunger pump fluid cylinder.
5. High Pressure Check Valves:
 Must be rated at or above the- well service plunger pump’s maximum pressure rating.
 Must be installed in the packing lube port so that the direction of flow is into the fluid
cylinder.
6. Packing Lube System Flow Requirements/Adjustments:
 After filling with the proper grade of packing lubricant rock drill oil, and before rotating the well
service plunger pump, the lube system should be adjusted to supply oil to each plunger and
packing assembly.
 Weir Oil & Gas recommends a minimum of 1 pint per plunger per hour for adequate packing
lubrication. Results from SPM® internal tests support this although variables in packaging and
field operations may result in higher consumption rates.
Minimum consumption rate 1.0 pint per plunger per hour
 Rates as high as 3 times the minimum recommended have been reported, and this should be
considered when sizing the lube reservoir.

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Recommended Plunger Lube Oils:

Selecting the proper plunger lube oil is very important to obtaining long life from the pumps plungers and
packing assemblies. The use of a superior plunger lubricant will also reduce horsepower robbing friction,
reduce fuel consumption, and increase the net amount of hydraulic horsepower delivered by the pump. Weir
Oil & Gas highly recommends the use of a modern “Rock Drill” for improved lubrication of the plungers and
packing. If “Rock Drill” is not available, a suitable “Way Oil” may be substituted.
Weir Oil & Gas recommends the use of Rock Drill or Way Oil that meet the following specifications:

ISO Grade 68 100

API Gravity 29.4 28.2
Viscosity, Kinematics
cSt at 40°C 70 104
cSt at 100°C 9 12
Viscosity, Saybolt
SUS at 100°F 362 556
Viscosity Index 103 99
Flash Point, C(F) 248 (478) 254 (489)
Pour Point, C(F) -27 (-17) -24 (-11)

The following types of plunger lube “Way Oil” are recommended for use in various ambient conditions as
shown:
General Service – for ambient conditions above 32 degrees F:
 “Way Oil 220” or equivalent

Cold Temperature Service – for ambient conditions below 32 degrees F:

 “Way Oil 68” or equivalent

NOTE: LUBRICANTS WHICH DIFFER SIGNIFICANTLY FROM THOSE SHOWN ABOVE ARE UNACCEPTABLE
AND MAY RESULT IN A MUCH SHORTER PLUNGER AND PACKING LIFE OR PREMATURE FAILURE OF
THESE COMPONENTS.
NOTE: PROPER LUBRICATION IS CRITICAL DURING THE STARTUP OF THE PLUNGER PUMP. THE
PLUNGER LUBRICANT MUST BEGIN TO FLOW FREELY TO THE STUFFING BOX LUBE INLET PRIOR TO THE
PUMP’S STARTUP AND STROKING OF THE PLUNGERS.
NOTE: PUMPS WHICH HAVE SAT IDLE FOR ANY APPRECIABLE PERIOD OF TIME (TWO WEEKS OR MORE)
MUST HAVE THE PLUNGERS REMOVED, BE HAND COATED WITH PLUNGER LUBE OIL, AND
REINSTALLED PRIOR TO OPERATION UNDER POWER. THE ELASTOMERIC PACKING RINGS WILL
EVENTUALLY STICK TO THE PLUNGER SURFACE AND WILL BECOME DAMAGED UPON STARTUP IF NOT
RE-LUBRICATED AS NOTED ABOVE.

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When using a SPM® air operated plunger lube system, the audible sound of the air operated lubricant pump
stroking once every one to two seconds will be an indicator of satisfactory plunger and packing lubrication.

For all styles of packing, the plunger lube is absolutely critical for good packing and plunger life. Failure to
provide adequate or appropriate lube will cause the packing to fail and cause damage to mating components.

NOTE: LUBRICANTS THAT FAIL TO MEET THESE SPECIFICATIONS, AND ESPECIALLY “USED CRANKCASE
OILS”, ARE UNACCEPTABLE.

STARTUP IS A CRITICAL TIME FOR PLUNGER PACKING. LUBRICATION SHOULD FLOW FREELY TO
PLUNGER PRIOR TO STROKING THE PUMP. STROKING DRY PLUNGERS CAN CAUSE THE HEADER RING,
PACKING, AND ELASTOMER’S TO TEAR AND FAIL.

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Recommended Plunger Grease Lube System:

If the end-user is going to modify the lubrication system to use grease, at their discretion, the plunger packing
wiper ring MUST be flipped in the packing nut to allow a path for the excess grease to escape the packing bore
chamber. Weir Oil & Gas recommends the use of a double or triple “ought” grease; 00 or 000.

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Plunger Lube Circuit Diagram:

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Supercharging System Requirements:

Due to the high-speed design characteristics associated with well service plunger pumps, supercharging the
SPM Well Service Pump is a must. The nature of well service operations (extreme variations in flow rates
coupled with the pumping of heavy slurries) requires a well-designed supercharge system. The supercharging
system must deliver an adequate supply of fluid to the plunger pump’s suction manifold at high enough
pressures and low enough flow velocities to prevent the pump from starving for fluid, while at the same time
maintaining fluid flow velocities high enough to keep solids suspended in the fluid slurry. A well-designed
supercharging system is extremely important in avoiding the harmful effects of cavitation and insuring trouble-
free service from the SPM® Well Service Pump. A well-designed supercharging system will meet the following
guidelines:

Primary Suction Piping and Hoses:

These are defined as the piping where the fluid first begins to flow from its source through gravity flow or
atmospheric pressure only. This portion of the system is usually a pipe or hose which connects the fluid
reservoir to the charge pump or blender suction pump. The flow velocity (based on the plunger pump’s
maximum flow rating with the size plunger being used) in this portion of the system must not exceed 4 ft. per
second in order to flow freely under atmospheric pressure or gravity flow. Other guidelines are as follows:

 Hoses must be oil and chemical resistant wire reinforced combination vacuum/discharge hose rated
at 300” Hg/150 PSI minimum.
 If steel piping is used; all piping runs must be installed so that they are level or progressively higher
toward the plunger pump in order to prevent air traps in the system. When used, reducer fittings
should be of the eccentric type and installed “belly down” in order to prevent air traps. All welded
connections must be air and fluid tight.
 All piping or hoses in this portion of the system should be kept as short as possible (10 ft. or less and
should be free of excessive bends and turns).

Centrifugal Supercharge Pump/Mixing Pump:

Some well servicing operations require the use of two centrifugals - one for mixing a slurry and the other for
supercharging the plunger pump. When two centrifugals are used, they must both meet the following
guidelines:

 Must be capable of delivering the rated maximum flow of the plunger pump while maintaining 80
PSI (185 ft. head) at the plunger pump suction inlet during all phases of the well service job.
 Must be sized appropriately to overcome any friction losses in the piping between the centrifugal’s
discharge and the plunger pump’s suction inlet. For example, depending on the length and the
layout of the piping, the centrifugal may have to be sized to deliver the required flow at higher
pressures at its discharge in order to maintain 80 psi (185 ft. head) at the plunger pump suction
inlet.
 Must be operated at a speed which will deliver the required flow within the upper 25% of its
efficiency range in order to assure adequate fluid acceleration on demand from the plunger pump.
 Must be adequately powered to deliver the plunger pump’s fluid requirements based on volume,
pressure, and the specific gravity of the fluid or slurry.

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Secondary Suction Piping and Hoses:

These are defined as the piping that carries fluid under pressure from the discharge of the centrifugal pump to
another point in the system. This is the piping which connects the centrifugal charge pump to the plunger
pump suction inlet and can also be the piping which connects the centrifugal mixing pump’s discharge to a
mixing tub inlet. The flow velocity in this portion of the system (based on the plunger being used) should
range from 8 to 12ft. per second. Other guidelines are as follows:

 Hoses must be oil and chemical resistant wire reinforced combination vacuum/discharge hose rated
at 203” Hg/100 PSI minimum.
 If steel piping is used; all piping runs must be installed so that they are level or progressively higher
toward the plunger pump in order to prevent air traps in the system. When used, reducer fittings
should be of the eccentric type and installed “belly down” in order to prevent air traps. All welded
connections must be air and fluid tight.
 All piping and hoses in this portion of the system should be kept as short as possible (10 ft. or
less) and should be free of excessive bends and turns.

Suction Pulsation Dampener (when a suction stabilizer dampening manifold is not used):
Due to the plunger pump’s positive displacement design, a naturally occurring fluid rhythm is generated in the
supercharge system as the fluid stops and starts at each suction valve. The varying pressure signal created by
this fluid rhythm reduces the effectiveness of the charge pump unless the pressure signal is dampened out of
the system. A suction pulsation dampener will help insure adequate fluid acceleration when each suction valve
opens, will help prevent cavitation, and will result in a much smoother operating pump. Guidelines for using a
suction pulsation dampener are as follows:

 The pulsation dampener should be of the nitrogen charged bladder type rated at 150 PSI
minimum.
 Should be installed above the fluid flow path so that solids in the fluid cannot settle and pack
around the bladder.
 Should be installed as close as possible to the plunger pump’s suction manifold inlet side for
maximum effectiveness.
 Must be pre-charged according to the manufacturer’s recommendations (usually 60% to 80% of
the anticipated supercharge pressure).

CAUTION: BLADDER OR CLOSED CELL FOAM TYPE UNITS ARE NOT RECOMMENDED FOR CO2 SERVICE.
ALSO, CHECK BLADDER COMPATIBILITY TO THE FRAC FLUID BEING PUMPED.

WARNING: FOR CO2 SERVICE, USE AN SPM® CO2 APPROVED SUCTION MANIFOLD WITHOUT A
SUCTION STABILIZER. USING NON-RATED EQUIPMENT CAN RESULT IN PRESSURE VESSEL FAILURE DUE
TO THERMAL SHOCK. INJURY OR DEATH CAN RESULT FROM USING EQUIPMENT NOT RATED FOR CO2
SERVICE. NO VIC GROOVE END CONNECTIONS, HAMMER UNION ONLY.

Supercharge Pressure Gauge:

 A supercharge pressure gauge should always be used in the system and should meet the following
guidelines:
 Should be a liquid filled 0 to 150 PSI pressure gauge.
 Should be installed as close to the plunger pump suction inlet as possible for maximum accuracy.
 Should be used with a gauge snubber or a needle valve which can be adjusted to act as a snubber.

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Adequate Feed To Pump:

The Quintuplex plunger pump is a relatively smooth operating unit. Its suction (and discharge) profile reflects
a plus 2% and minus 5% variation from its average discharge rate (See Fig. 1). Nevertheless, this continual
variation in fluid demand (as much as 7%) can produce fluid dynamic problems.

The proper supply of fluid to the pump inlet is a complex issue. Sufficient initial pressure and recovery
capability of the charge pump (Item 2), and the use of a pulsation dampener (Item 4) only begin to address the
fluid dynamics requirement of the plunger pump.

Inadequate mixture of solids and liquids along with discharge fluid resonance can combine to create cavitation,
water hammer, and ultimate damage to the equipment.

A balance must be struck as the fluid passes through the suction manifold and enters the fluid cylinder. Fluid
velocity should be sufficiently high to keep the solids in suspension, but not so much that friction robs the
charge pump’s ability to respond to the instantaneous demand of the plunger pump.

Due to space limitations, the suction manifold is generally mounted horizontally (See Fig. 2) and
fluid is usually provided to one end of the manifold. This arrangement requires the fluid to travel
horizontally and then make an abrupt 90 transition to enter the cylinder’s suction valves.
While this is the most popular method for manifolding, its limitations have become evident as rates and
pressures have increased, and liquid/solids compositions have changed. There is a strong evidence that the
fluid mixture can breakdown in the suction manifold resulting in solids separating from the liquid. This
tendency becomes more pronounced the further the fluid has to travel from the manifold inlet.

If there is sufficient solid separation, cavitation will ensue at that location. And resulting suction and discharge
valve damage can occur at the cylinder bore furthest from the manifold inlet. In extreme cases, damage to the
associated power end components can also occur.

SPM® strongly recommends the use of either the dual feed manifold or the zoomie manifold.

A dual feed system can be created utilizing the standard “log” style manifold with a special attachment. The
sketch in Fig. 3 illustrates how a supplementary device can be added to allow fluid supply to both ends of the
manifold.

The zoomie style manifold is illustrated in Fig. 4.

Contact Weir Oil & Gas engineering for more material on these two styles.

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Supercharging System Operational Parameters:

1. Recommended Supercharge Pressure at plunger pump suction inlet: 80 PSI (185 ft. head) minimum to
100 PSI (230 ft. head) maximum.

NOTE: THE SUPERCHARGE PRESSURE MUST ALWAYS BE GREATER THAN THE VAPOR PRESSURE OF THE
FLUID BEING PUMPED.

CAUTION: ALLOWING VELOCITIES IN THE PRESSURIZED PORTION OF THE SYSTEM TO FALL BELOW
8FT/SEC IN WATER WILL RESULT IN THE FRAC SAND NOT REMAINING IN SUSPENSION AND CAN
RESULT IN SAND-OFF AND EQUIPMENT DAMAGE.

2. Number of 4” suction hoses required to maintain 4 ft. per second maximum fluid velocity in “gravity
feed” portion of the system:
GPM FLOW BPM FLOW NUMBER OF 4” HOSES REQ’D
Up to: 157 3.7 One
Up to: 313 7.5 Two
Up to: 470 11.2 Three
Up to: 626 14.9 Four
Up to: 783 18.6 Five
Up to: 940 22.4 Six
Up to: 1096 26.1 Seven
Up to: 1253 29.8 Eight
Up to: 1724 41.0 Eleven
Up to: 1894 45.1 Twelve

3. Steel pipe size required to maintain 4 ft. per second maximum fluid velocity in “gravity feed” portion of
the system:
GPM FLOW BPM FLOW PIPE SIZE REQ’D
Up to: 156 3.7 4” I.D.
Up to: 250 5.9 5” I.D.
Up to: 353 8.4 6” I.D.
Up to: 626 14.9 8” I.D.
Up to: 979 23.3 10” I.D.
Up to: 1410 33.6 12” I.D.
Up to: 1708 40.7 13¾” I.D.
Up to: 2269 54.0 15¼” I.D.

4. Number of 4” suction hoses required to maintain 12 ft. per second maximum fluid velocity in the
“pressurized” portion of the system:
GPM FLOW BPM FLOW NUMBER OF 4” HOSES REQ’D
Up to: 470 11.1 One
Up to: 940 22.3 Two
Up to: 1409 33.5 Three
Up to: 1894 45.1 Four

5. Steel pipe size required to maintain 12 ft. per second maximum fluid velocity in the “pressurized”
portion of the system.
GPM FLOW BPM FLOW PIPE SIZE REQ’D
Up to: 264 6.2 3” I.D.
Up to: 470 11.1 4” I.D.
Up to: 734 17.4 5” I.D.
Up to: 1057 25.2 6” I.D.
Up to: 1894 45.1 8” I.D.

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Recommended Practice for Pump Packing:

Cement Service (Fig. 1)

Technique:
Cement service can be divided into two distinct services; primary and remedial. Primary cementing is
performed during the well construction, or drilling phase. Cement slurry is pumped down casing and displaced
into annulus created between the casing and formation. Remedial cementing is performed during the well
remedial phase. Cement slurry is pumped into the casing and is forced, or “squeezed” against the formation
through open holes, perforations, or a hole in the casing.

In practice, most cement jobs are at relatively low pressure and high flow rates requiring modest power to the
pump. High squeeze pressure should be for very short duration. Note max recommended pressures in the
pump performance chart.

WARNING: DO NOT RUN THE PUMP AT HIGHER PRESSURE THAN THE RATING OF THE DISCHARGE
FLOW IRON OR INJURY, DEATH, PUMP DAMAGE OR ENVIRONMENTAL DAMAGE COULD OCCUR.

Packing Components: “Rubber Spring Loaded” (See Fig 1– page 17)

Packing for this process is made up of a Header Ring and one ‘SSF’ Style Pressure Rings.

Header Ring
Made from an 80 durometer homogeneous nitrile, the Header Ring is designed primarily to be used with 'SSF'
and 'ASF' design V-rings where slurries and other large particle containing fluids are being pumped. The design
of the Header Ring keeps the product being pumped from working its way into the seal ring area and causing
premature failure of the seal or the packing gland. Simultaneously, the Header Ring acts as a spring to create a
non-adjustable packing set. This is intended to add greater service life to the packing and cut down on the
maintenance time commonly associated with slurry pump applications due to the need to tighten the packing
nut.

CAUTION: BETWEEN STAGES ENSURE THAT THE PACKING NUT HAS NOT BACKED OFF. FAILURE OF
SEAL, GLAND OR MECHANICAL COLLISION OF THE PACKING NUT WITH THE PLUNGER CLAMP CAN
RESULT.

Pressure Rings
These components are a double stack height single pressure ring 'SSF' Vee design. They are composed of TFE
modified nitrile binder with cotton and synthetic fabric reinforcement (1069).

 Recommended for cementing and general fracturing fluids and weak acids. Not recommended for
Toluene or Xylene stimulation.

Extreme service ‘SSF’ packing

Extreme service packing is a HBR packing reinforced by synthetic fibers and with poly cotton to exchange
lubrication wicking.

 Recommended for cement, hydrocarbons, most frac fluids and mild acids.

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WARNING: DO NOT SERVICE THE FLUID END TO CHANGE PACKING, PLUNGERS, VALVE SEATS OR
SEALS UNTIL THE PUMP IS LOCKED OUT/TAGGED OUT AND ISOLATED FROM WELL BORE PRESSURE,
SUCTION INLET PRESSURE, AND PRIOR TO RELIEVING THE PRESSURE WITHIN THE FLUID CYLINDER.
FAILURE TO DO SO COULD LEAD TO SERIOUS INJURY OR DEATH.

CAUTION: REPLACING PACKING, PLUNGERS, VALVES, VALVE SEATS REQUIRE OPENING UP THE FLUID
PUMPING CHAMBER. USE A VALVE LIFT TOOL TO DRAIN THE FLUID FROM THE CHAMBER PRIOR TO
COMMENCING. FAILURE TO DO SO WILL RESULT IN A FLUID SPILL.

WARNING: REMOVING SUCTION OR DISCHARGE COVERS WITH A NITROGEN FILLED SUCTION

STABILIZER CAN RESULT IN INJURY OR DEATH IF THE NITROGEN BLADDER RUPTURES.

NOTE: YOUR PACKING SET MAY BE DIFFERENT THAN WHAT IS SHOWN.

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Acid/Frac Service (Fig 2)

Technique:
Fracturing
Hydraulic fracturing is generally applied to hard tight sandstone reservoirs from which commercial production
would not be otherwise feasible. The process consists of hydraulic pressure against the formation by pumping
fluid into the well. While splitting the formation by hydraulic pressure, the fluid also will convey sand or other
propants into the fissures keeping them open after the pressure is released.
 Fluids for this procedure include various combinations of refined oil, crude oil, salt water, acids,
emulsifiers, and other additives.
 Sand laden fluids in the 8 to 10 pounds per gallon range are common, with higher values being
continually achieved.
 This procedure generally requires high pressure, high rate operations, which require large amounts
of power.

WARNING: DO NOT OPERATE AT PRESSURES ABOVE THE PRESSURE RATING OF THE FLOW IRON OR
INJURY, DEATH, PROPERTY OR ENVIRONMENTAL DAMAGE COULD RESULT.

Acid Treatment
Acidizing is the technique where predominantly hydrochloric acid is pumped into the well followed by a water
flush. Hydrochloric acid works well on natural or induced fractures of limestone and dolomite. With the
dissolving effect of the acids, the formation can be opened to allow better access to the reservoir. Hydrofluoric
acid will dissolve clays and sand like substances, and mixed with hydrochloric acid, it will dissolve the mud
deposits in the pore space of a producing formation adjacent to the well. Usually chemical inhibitors are
combined with the acid to prevent corrosion to well components.

Packing Components: “Rubber Spring Loaded”

Header Ring
 For general fracturing fluids and weak acids the 80 durometer homogeneous nitrile header ring
described in the “Cement Service” section is preferred.
 For fluids containing light diesel or aromatics, an 80 durometer acrylic-nitrile header ring is more
suitable.

CAUTION: NEITHER OF THE TWO AVAILABLE HEADER RINGS ARE SUITABLE FOR TOLUENE OR XYLENE
STIMULATION.

Pressure Rings
These components are double stack height 'SSF' Vee design. They are different than the ones described in the
“Cement Service” section and are composed of a special modified Nitrile binder with special fabric
reinforcements (1067). They are recommended for cementing and all known fracturing and stimulation fluids,
and all stimulation acids up to 28% concentration.

Extreme service ‘SSF’ packing

Extreme service packing is a HBR packing reinforced by synthetic fibers and with poly cotton to enhance
lubrication wicking. Recommended for cement, hydrocarbons, most frac fluids and mild acids

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NOTE: IF THE END-USER IS GOING TO MODIFY THE LUBRICATION SYSTEM TO USE GREASE, AT THEIR
DISCRETION, THE PLUNGER PACKING WIPER RING MUST BE FLIPPED IN THE PACKING NUT TO
ALLOW A PATH FOR THE EXCESS GREASE TO ESCAPE THE PACKING BORE CHAMBER. WEIR OIL & GAS
RECOMMENDS THE USE OF A DOUBLE OR TRIPLE “OUGHT” GREASE; 00 OR 000.

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Tach Drive/Rate Meter Calibration Specifications:

PLUNGER * FLUID DISPLACEMENT

DIAMETER INCHES PER TACH DRIVE REVOLUTION PER TACH DRIVE REVOLUTION @ 100%
@ 95% V.E. V.E.
(MM) GPR BPR LPR GPR BPR LPR
3¼” (82.6) .2148 .00511 .8130 .2261 .00538 .8558

3½” (88.9) .2491 .00593 .9429 .2622 .00624 .9926

3¾”(95.3) .2860 .00681 1.0825 .3010 .00717 1.1394

4” (101.6) .3254 .00775 1.2316 .3425 .00816 1.2964

4½ (114.3) .4118 .00981 1.5587 .4335 .01032 1.6408

5” (127.0) .5084 .01211 1.9244 .5352 .01274 2.0257

5½” (139.7) .6152 .01465 2.3285 .6476 .01542 2.4510

5¾” (146.1) .6724 .01601 2.5450 .7078 .01685 2.6789

6” (152.4) .7321 .01743 2.7711 .7707 .01835 2.9169

6½” (165.1) .8592 .02046 3.2522 .9045 .02153 3.4234

NOTE: THE VOLUMETRIC EFFICIENCY AND RESULTING DISPLACEMENT WILL VARY SLIGHTLY DUE TO
OPERATIONAL FACTORS SUCH AS PUMP SPEED, SUPERCHARGE CONDITIONS, AND THE SPECIFIC
GRAVITY OF THE FLUID BEING PUMPED.

V.E. = VOLUMETRIC EFFICIENCY OF PUMP

GPR = U.S. GALLONS PER REVOLUTION
BPR = U.S. BARRELS PER REVOLUTION
LPR = LITER PER REVOLUTION

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Startup and Break-In Procedure:

Each new pump must undergo a brief but thorough startup and break-in procedure in order to verify the field
worthiness of the unitized pumping system and in order to allow a gradual “wearing in” of various mating
parts in the pump itself. The following guidelines have been established by Weir Oil & Gas to minimize startup
problems and insure maximum service from the plunger pump:

A. Inspection Prior to Starting Engine:

1. Check to see that all masking tape, rust preventative, etc. has been removed from moving parts
such as pony rods, plungers, pinion shaft, etc.
2. Check to see that the plunger pump is securely bolted to the skid or truck frame.
3. Check to see that the driveline is securely fastened to the plunger pump’s input shaft and that
adequate slip is present in the driveline’s slip joint.
4. Check to see that the power end lube oil reservoir has been flushed and drained then filled with
the proper type of gear oil.
5. Check to see that the plunger lube oil reservoir has been flushed and drained then filled with the
proper type of rock drill oil.
6. Check to see that the supercharge piping system has been completely flushed and all piping
connections are tight.
7. Check to see that the power end lube system startup adjustments and plunger lube system
startup adjustments have been performed.
8. Check to see that the suction pulsation dampener has been recharged properly.
9. Check to see that the primary suction piping is connected to an adequate supply of cool clean
water for testing. Check to see that all connections are tight and supply valves open.
10. Check to see that the plunger pump’s discharge piping is safely installed all the way back to the
water reservoir. Check to see that all connections are tight and all valves are open.
11. Follow the engine manufacturer’s recommendations for engine startup and warm-up.

B. Warm-up Procedure Prior to Rotating the Plunger Pump:

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

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C. Plunger Pump Valve Seating Procedure:

1. In order to protect the fluid cylinder from washing before sustained pumping begins, the tapered
valve seats must be pressured up and fully seated creating a positive fluid seal.
2. Adjust the test choke for high pressure/low pump RPM. Shift the transmission to 1st gear and
slowly increase the throttle setting to achieve 85% of the pump’s maximum rated rod load for 2
to 3 minutes or until a series of audible popping noises are heard indicating that the seats have
seated in the taper. The desired pressure for each plunger size is as follows:

Plunger Dia. 85% Rated Pressure

3½” 17,000 PSI
3¾” 14,800 PSI
4” 13,000 PSI
4½” 10,300 PSI
5” 8,300 PSI
5½” 6,900 PSI
5¾” 6,300 PSI
6” 5,800 PSI
6½” 4,900 PSI

During this portion of the startup procedure, closely observe the plunger pump for any unusual
noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as elapsed time,
ambient temperature, power end lube oil temperature, power end lube oil pressure, supercharge
pressure, etc. After returning the engine to idle and transmission to neutral, physically inspect
the plunger pump before proceeding further.

D. Break-In Procedure:
1. Adjust the test choke, engine, and transmission to obtain approximately 32% rated rod load,
40% rated pump RPM, and 38% rated horsepower. These settings should be approximately as
follows:

Plunger Dia. Pump RPM GPM/BPM PSI BHP

3½” 130 217/5.2 6,400 900
3¾” 130 248/5.9 5,600 900
4” 130 282/6.7 4,900 900
4½” 130 358/8.5 3,900 900
5” 130 442/10.5 3,100 900
5½” 130 534/12.7 2,600 900
5¾” 130 584/13.9 2,400 900
6” 130 636/15.1 2,200 900
6½” 130 746/17.8 1,850 900

Run the plunger pump at this setting for one hour. During this time, closely observe the plunger
pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end lube oil
pressure, supercharge pressure, etc. After returning the engine to idle and the transmission to
neutral, physically inspect the plunger pump before proceeding further.

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2. Adjust the test choke, engine, and transmission to obtain approximately 52% rated rod load, 50%
rated pump RPM, and 75% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM GPM/BPM PSI BHP

3½” 160 267/6.4 10,400 1800
3¾” 160 306/7.3 9,050 1800
4” 160 347/8.3 8,000 1800
4½” 160 440/10.5 6,300 1800
5” 160 544/13.0 5,100 1800
5½” 160 658/15.7 4,200 1800
5¾” 160 718/17.1 3,850 1800
6” 160 782/18.6 3,500 1800
6½” 160 918/21.9 3,000 1800

Run the plunger pump at this setting for one hour. During this time, closely observe the plunger
pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end lube oil
pressure, supercharge pressure, etc. After returning the engine to idle and the transmission to
neutral, physically inspect the plunger pump before proceeding further.

3. Adjust the test choke, engine, and transmission to obtain approximately 26% rated rod load, 100%
rated pump RPM, and 77% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM GPM/BPM PSI BHP

3½” 330 551/13.1 5,200 1850
3¾” 330 630/15.0 4,500 1850
4” 330 716/17.0 4,000 1850
4½” 330 908/21.6 3,150 1850
5” 330 1,122/26.7 2,550 1850
5½” 330 1,356/32.3 2,100 1850
5¾” 330 1,482/35.3 1,900 1850
6” 330 1,619/38.5 1,800 1850
6½” 330 1894/45.1 1,500 1850

Run the pump at this setting for 30 minutes. During this time, closely observe the plunger pump for
any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as
elapsed time, ambient temperature, power end lube oil temperature, power end lube oil pressure,
supercharge pressure, etc. After returning the engine to idle and the transmission to neutral,
physically inspect the plunger pump before proceeding further.

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4. Adjust the test choke, engine, and transmission to obtain approximately 100% rated rod load, 20%
rated pump RPM, and 58% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM GPM/BPM PSI BHP

3½” 65 109/2.6 20,000 1410
3¾” 65 124/3.0 17,420 1410
4” 65 141/3.4 15,315 1410
4½” 65 179/4.3 12,100 1410
5” 65 221/5.3 9,800 1410
5½” 65 267/6.4 8,100 1410
5¾” 65 292/7.0 7,410 1410
6” 65 318/7.6 6,805 1410
6½” 65 373/8.9 5,800 1410

Run the pump at this setting for 30 minutes. During this time, closely observe the plunger pump for
any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as
elapsed time, ambient temperature, power end lube oil temperature, power end lube oil pressure,
supercharge pressure, etc. Return the engine to idle, the transmission to neutral, and kill the
engine.

5. Visually inspect the power end for oil leaks around the pony rod seals, pinion seal, lubrication hoses,
lube drain hoses, covers, etc.

Visually inspect the fluid end for fluid leaks around the suction covers, discharge covers, discharge
flanges, stuffing boxes, and suction manifold. Visually inspect the plungers for any signs of heating
or scoring.

Remove the power end lube system magnet and inspect for any unusually large particles of metal.
Change the lube oil filters.

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SECTION III: Maintenance and Repair

Routine Preventative Maintenance:
Maximum service and trouble-free operation can be obtained from the SPM® well service plunger pump by
establishing a thorough preventive maintenance program as follows:

During The First 100 Hours of New Pump Operation:

 Change power end lube oil filters every 25 hours (or more often if required) to prevent filter bypass.
 Thoroughly clean the power end lube oil suction strainer after the first 50 hours and 100 hours
operation.
 Change the power end lube oil after the first 100 hours operation and clean the lube oil reservoir.

Daily Preventive Maintenance:

 Check the oil level in the power end lube oil reservoir.
 Check the oil level in the plunger lube oil reservoir.
 Check the plunger pump for oil leaks and/or fluid leaks.
 Check the power end lube oil system for leaks.
 Check the plunger lube system for leaks.
 Check the supercharge piping for leaks.
 Visually check for loose bolts in the following locations:
 Power End mounting bolts.
 Stay Rods.
 Discharge Flanges.
 Companion Flange.
 Packing Nuts.
 Retainer and Discharge Nuts.
 If the suction stabilizer has a nitrogen filled bladder, check the nitrogen charge pressure and
correct as needed. Follow the manufacturer’s charging pressure recommendations, usually 60%-
80% of suction inlet pressure.

Weekly Preventive Maintenance:

 Check all items on “daily” list.
 Check all valves, inserts, valve seats, and springs.
 Check all discharge and suction cover seals.
 Check suction pulsation dampener for correct pre-charge.

Monthly (or every 100 hours) Preventive Maintenance:

 Check all items on “daily” and “weekly” lists.
 Check all fluid cylinder mounting bolts to insure that they are tight with a torque wrench.
 Check all plunger pump-mounting bolts to insure that they are tight.
 Change power end lube oil filters.
 Check all supplies needed for routine maintenance such as o-rings, fluid seals, valves, valve inserts, valve
seats, valve springs, packing, oil seals, filter elements, etc.

Quarterly (or every 250 hours) Preventive Maintenance:

 Check all items on “daily”, “weekly”, and “monthly” list.
 Change the power end lube oil and refill with the proper grade of gear oil for upcoming ambient
conditions.
 Thoroughly clean the power end lube oil suction strainer.
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Quarterly (or every 250 hours) Preventive Maintenance (Cont.):

 Remove and inspect the plungers and packing assembly components. Replace all packing pressure
rings and header rings.
 Clean the plunger pump’s oil breather and the power end lube oil reservoir breather.

Yearly (or as required) Preventive Maintenance:

 Replace worn plungers and packing brass.
 Replace worn or corroded valve covers, suction valve stops, packing nuts, discharge flanges, pump
tools, etc.
 Replace all discharge flange seals and suction manifold seals.
 Replace any defective gauges and instruments.
 Inspect (and rebuild if necessary) the power end lube oil pump.
 Inspect the shell bearings for wear. Retorque connecting rod housing bolts to correct torque values.

It is difficult to assess wear and tear on a pump based solely on hours operated, due to the variations in duty
cycle and types of service. However, roller bearings, rod bearings and gearing may need replacing after
approximately 1200 to 3000 hours. With either component, signs of extensive wear will generally show up as
spalling, or flaking off, of material causing pitting or scoring on the working surfaces. A small amount of this is
tolerable on gear faces, but any spalling on a bearing surface is an indication to replace that item as quickly as
feasible.

While replacement of these major components is relatively expensive, failure of a main bearing can quite often
lead to power frame, crankshaft, or other serious damage.

Close observation of the lube oil filters during routine maintenance will generally indicate the condition of roller
bearings, gears, and journal bearings. A routine of pulling the inspection covers and observing the condition of
the bearings and gears every 500 hours is recommended.

Expendable Components:

A. Expendable life improvement techniques:

a. Valves and valve seats
Valves and valve seats wear out faster than any other expendable due to valve seat damage from
frac sand and cavitation corrosion pitting. Valve life can be extended by keeping valve-flow-
through velocities below 12ft/sec and by using a properly sized, correct style and properly
installed pulsation suction stabilizer.

WARNING: VALVES AND VALVE SEATS MUST BE REPLACED PRIOR TO FAILURE. FAILURE OF A
DISCHARGE AND SUCTION VALVE IN THE SAME PLUNGER PRESSURE CHAMBER CAN RESULT IN
DISCHARGE (WELL BORE) PRESSURE ENTERING THE SUCTION MANIFOLD. FAILURE OF THE SUCTION
MANIFOLD, SUCTION FLOW LINES OR HOSES CAN RESULT. INJURY, DEATH OR ENVIRONMENTAL
DAMAGE CAN OCCUR. USE OF A CHECK VALVE IN THE FLOW LINE IS RECOMMENDED.

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Expendable Components (Con’t):

b. Fluid End
Fluid Ends commonly fail by cracking in the crossbore. The time of failure can be extended by a
properly sized suction stabilizer. If it is a nitrogen bladder type, check the charge pressure before
each job.

NOTE: WHEN CHANGING VALVES USE A MIRROR AND FLASHLIGHT TO CHECK FLUID CYLINDER FOR
CRACKS.

c. Plungers
Plungers should be replaced if the hard coating is worn or if they have dents or dings.

d. Packing
Packing should be replaced prior to failure. Packing failure can lead to washout of the packing
gland. Between stages, check to see that all packing nuts are tight.

CAUTION: FAILURE TO PROPERLY MAINTAIN PACKING OR ALLOWING THE PACKING NUT TO LOOSEN
CAN RESULT IN ENVIRONMENTAL DAMAGE.

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Troubleshooting Guide:
TROUBLE SYMPTOM: PROBABLE CAUSE:
A.) Abnormally high vacuum at power 1. Extremely cold ambient temperature/dangerously high
end lube pump suction inlet (may oil viscosity.
or may not be accompanied by 2. Clogged lube system suction strainer.
abnormally low oil pressure). 3. Kinked or collapsed lube system suction hose.
4. Clogged oil reservoir breather.
5. Erroneous gauge reading.

B.) Abnormally low power end lube 1. Leak in lube pump suction piping, which allows air to be
oil pressure with normal to low drawn into the system.
vacuum reading at lube pump 2. Worn or damaged lube pump.
suction (may or may not be 3. Leak in lube pump pressure piping.
accompanied by high oil 4. Low oil level in reservoir.
temperature). 5. Clogged oil filter element.
6. Faulty lube system relief valve.
7. Extremely hot lube oil temperature/dangerously low oil
viscosity.
8. Erroneous gauge reading.

C.) Abnormally high power end lube 1. Extremely warm ambient temperature/dangerously low
oil temperature (may or may not oil viscosity/incorrect grade of gear oil.
be accompanied by low oil 2. Gear oil contaminated with water, trash, or air bubbles.
pressure). 3. Plunger pump has been operated continuously for too
long a period of time at or near its maximum
horsepower or torque rating.
4. Heat exchanger or oil cooler malfunction.
5. Erroneous gauge reading.
6. Internal power end damage or power end wear.

D.) Leaking power end oil seals. 1. Extremely cold ambient temperature/high oil viscosity.
2. Damaged seal surface on mating part.
3. Clogged oil breather/high crankcase pressure.
4. Worn or damaged seal.
5. Contaminated lube oil.
6. Loose inspection cover bolts or torn inspection cover
gaskets or sealing bonded inspection cover bolt washers.

E.) Leaking lube lines. 1. Loose fittings or damaged hoses.

F.) Leaking fluid end seals. 1. Seal installed improperly.

2. Seal cut or pinched on installation.
3. Mating seal surface not cleaned properly prior to seal
installation.
4. Damaged or corroded mating seal surface.
5. Sealing part not properly tightened.

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TROUBLE SYMPTOM: PROBABLE CAUSE:

G.) Plunger and/or packing fluid leak. 1. Packing nut not tightened properly.
2. Worn or damaged packing.
3. Packing installed improperly.
4. Mating seal surface not cleaned properly prior to packing
installation.
5. Damaged or corroded mating seal surface.
6. Fluid being pumped is incompatible with the style packing
being used.
7. Wiper ring damaged or installed improperly.

H.) Fluid knock or hammer. 1. Air entering supercharge system through loose, worn or
damaged connections.
2. Air entering supercharge system through leaking charge
pump seals.
3. Fluid being pumped contains gas or vapor.
4. Insufficient supercharge flow or pressure.
5 Valve cocked open/broken valve spring or valve stop.
6. Worn or damaged valve, valve insert, or valve seat.
7. Improperly charged or ineffective suction pulsation
dampener.

I.) Low discharge pressure/rough 1. Worn or damaged valve, assembly.

running pump. 2. Insufficient supercharge flow or pressure.
3. Air, gas, or vapor in fluid being pumped.
4. Improperly charged or ineffective suction pulsation
dampener.
5. Two or more plunger pumps being supercharged by a
common charge pump and getting “in phase” with each
other.

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Revision: E

SPM® QWS2500 SD Fluid End Repair Procedures:

To remove Valves and seats:
1. Using the SPM® 2” hex cover wrench and a 10 lb. Hammer, remove the suction and discharge
cover retainer nuts from the fluid cylinder.
2. Using the SPM slide hammer, remove all five discharge covers and all five suction covers.
3. For Grooveless fluid ends; remove the suction valve stops following the reverse order of directions
within pages 44-46.
4. For Grooved fluid ends; turn the five suction valve stops by hand approximately 90 degrees and
remove them from the fluid cylinder. (see pages 49-50)
5. Remove all valve springs from the fluid cylinder suction side.
6. Using an SPM® Magnetic Valve Removal Tool, cock each valve to one side in order to drain any
fluid trapped above it, and remove the valve from the cylinder. Follow the valve manufacturer’s
recommendation for removing the insert from the valve.
7. Using an SPM® Hydraulic Seat Puller Assembly, remove all five discharge valve seats, and all five
suction valve seats from their tapered bores in the cylinder. The tapered bores should be
inspected, cleaned thoroughly, and lightly hand polished with a 220 to 240 grit emory cloth prior
to installation of new seats.
8. Install a new o-ring seal on the valve seat prior to its installation in the fluid cylinder. Each valve
seat must be installed dry – never use grease, oil, or any other substance to coat the tapered
portion of the valve seat. After installing the valve seat hand tight in the taper, hammer it down
tight into the taper using an old valve and a heavy steel bar.
9. When installing new valve inserts, do not install one manufacturer’s valve insert on another
manufacturer’s valve. Likewise, when installing new valves, do not mix one manufacturer’s valve
with another’s valve seat. Install all ten valves in the valve seats.
10. Reinstall all ten valve springs carefully centering them on the valve.
11. Reinstall the suction valve stop following the directions on pages 44-46 for Grooveless and 47-48
for Grooved cylinders.
12. Before reinstalling the discharge and suction covers, clean the covers thoroughly, install new fluid
seals, and coat them with a light oil or grease. Inspect the primary seal backup for wear. Replace
if the backup has deteriorated. Clean the mating bores in the fluid cylinder and lightly hand
polish them with a 220 to 240 grit emory cloth. Reinstall the discharge covers and suction covers
using the SPM® Slide Hammer. Care must be taken to keep the discharge valve springs aligned
properly while installing the discharge covers.
13. Using the SPM® 2” hex cover wrench and 10 lb. hammer, reinstall the discharge and suction cover
retainer nuts. All ten retainer nuts should receive a light coating of anti-seize lubricant (RE: U.S.
Mil Spec. #MIL-S-907) on the threads and on the bottom face prior to installation.

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To Change Plungers and Packing:

1. Using a 3/8” hex key wrench, remove the two 1/2” socket head capscrews from each of the
plunger clamps. Separate the two halves of each plunger clamp and remove them being careful
to keep them in matched pairs. Inspect each clamp for wear or damage to the tapered shoulders
inside.
2. Using the SPM® packing nut tool, loosen each of the packing nuts at least one full turn.
3. Separate the plunger from the pony rod being careful to avoid damaging the mating face of
either.
4. Remove the suction covers as outlined earlier in “To Remove Valves & Seats”.
5. Slide each plunger away from the pony rod and out of the fluid cylinder through the suction cover
bore.
6. Completely remove each packing nut from the packing gland thread bore.
7. Using an aluminum bar and 2½” lb. hammer, lightly tap on the packing spacer – first to one side
and then the other – driving the packing assembly toward the power end – until each packing
ring falls out of the packing bore.
8. Inspect each plunger for wear, scoring, and corrosion on the hard surface area as well as wear on
the tapered plunger clapper flange and damage to the face which mates with the pony rod. The
mating face and tapered flange of each pony rod should also be inspected closely for wear or
damage prior to reinstalling the plungers.
9. Inspect each ring of packing brass for excessive wear and scoring.
10. Remove the plunger lube fitting above each packing bore and blow air through the lube port to
insure that the lube passage is unobstructed.
11. Each packing bore must be thoroughly cleaned and lightly hand polished with a 220 to 240 grit
emory cloth prior to packing reinstallation.
12. Using new packing header rings and new packing pressure rings, reinstall the packing assembly
one piece at a time (refer to the Packing Assembly diagram included in this manual). Each ring
should be installed with a coating of light oil only. Care must be taken to avoid damaging the
internal and external sealing lips of each packing ring.
13. Reinstall each packing nut, screwing it all the way in until tight, then backing it off one half turn.
14. Coat the hard surface area of each plunger with a light oil and insert it into the packing. Using a
block of hardwood and a 5 lb. hammer, bump the plunger into the packing while holding it as
straight as possible with the packing bore centerline. Continue bumping the plunger through the
packing until the clamp end nears the pony rod face. Carefully align the male boss on the plunger
with the female boss on the pony rod and bump the plunger up tight against the pony rod face.
15. Reinstall each plunger clamp on the plunger from which it was removed. Reinstall the 1/2” socket
head capscrews and tighten them evenly to the proper torque
(refer to drawing package for torque values).
16. Using the SPM® packing nut wrench, tighten each packing nut as tight as possible.

NOTE: THE PACKING NUT WILL NEED TO BE RETIGHTENED ONLY ONCE AFTER THE PUMP IS
REASSEMBLED AND RAN UNDER PRESSURE FOR A FEW REVOLUTIONS. AFTER THAT, THE PACKING IS
COMPLETELY SELF-ADJUSTING.

17. Reinstall the packing lube fitting above each stuffing box.
18. Reinstall the suction covers as outlined earlier in “To Remove Valves and Seats”.

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To Remove Discharge Flanges:

1. Using a 1⅝ ” wrench, remove the six 1” nuts from each of the two discharge flanges.
2. Remove each discharge flange from the fluid cylinder. Remove the fluid seals from both the inlet
side and outlet side of each discharge flange. Closely inspect each discharge flange for internal
erosion and corrosion. Inspect the discharge flange threads for wear and damage. The discharge
flange seal surfaces should be thoroughly cleaned and lightly hand polished with a 220 to 240 grit
emory cloth prior to reinstallation.
3. Inspect the fluid cylinder discharge flange bores for erosion and corrosion. Thoroughly clean and
lightly hand polish each bore with a 220 to 240 grit emory cloth prior to reinstalling the discharge
flanges.
4. Using new fluid seals and a coating of light oil, reinstall each discharge flange being careful to
avoid damaging the seal on the inlet side of the flange. Reinstall the six 1” hex nuts on each
flange and evenly tighten them to the proper torque (refer to the Torque Table included in this
manual).

To Remove the Suction Manifold:

1. Using a 15/16” wrench, remove the twenty 7/8” capscrews which secure the suction manifold to
the fluid cylinder, and drop the suction manifold away from the fluid cylinder.
2. Inspect the suction manifold for internal erosion and corrosion. Remove the five suction manifold
o-ring seals and inspect the seal grooves in the manifold for erosion and corrosion. Inspect the
face and O.D. of the pipe at each end of the manifold for erosion and corrosion.

NOTE: THE SPM® MANIFOLD INCORPORATES A VICTAULIC “ES” TYPE CONNECTION AT EACH END
WHICH WILL ACCEPT EITHER A VICTAULIC “END SEAL CUT GROOVE” GASKET OR A VICTAULIC
“STANDARD CUT GROOVE” GASKET. THE CONDITION OF THE FACE OF THE MANIFOLD IS
IMPORTANT FOR SEALING PURPOSES ONLY WHEN THE “END SEAL (ES)” GASKET IS USED.

3. Inspect the bottom face of the fluid cylinder for erosion and corrosion. Thoroughly clean and
lightly hand polish the bottom face of the fluid cylinder with a 220 to 240 grit emory cloth prior
to reinstalling the suction manifold.
4. Using new o-ring seals, reinstall the suction manifold. Reinstall the twenty 7/8” capscrews and
evenly tighten them to the proper torque (refer to drawing package for torque values).

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To Remove The Fluid End:

1. Remove the plunger clamps and separate each plunger from each pony rod as outlined earlier in
“To Change Plungers and Packing”.
2. Disconnect the plunger lube hoses and whatever discharge piping connections and suction piping
connections are necessary for fluid end removal.
3. Using a 2¾” wrench, remove the twenty 1¾” nuts which secure the fluid cylinder to the power
end stay rods. Remove the fluid cylinder from the power end.
4. Inspect the face of the fluid cylinder for wear or fretting around the stay rod holes. Inspect the
shoulders of the stay rods for wear or cracks. Check all twenty stay rod nuts for the correct torque
(2000 ft. lbs. with lubricated threads) prior to reinstalling the fluid cylinder.

NOTE: IF A HYDRAULIC POWERED TORQUE WRENCH IS NOT AVAILABLE, HAND TIGHTEN EACH STAY
ROD AS TIGHT AS POSSIBLE WITH A 2” END WRENCH, THEN TURN THE STAY ROD ANOTHER 30
DEGREES CLOCKWISE WITH AN OPEN END HAMMER WRENCH.

5. Reinstall the fluid cylinder. Clean and lubricate the stay rod threads, then hand tighten the 1¾”
nuts as tight as possible with a 2¾” wrench. If a hydraulic powered torque wrench is not available
to tighten the nuts to 2000 ft. lbs., turn each nut another 30 degrees past hand tight with a 2¾”
hammer wrench.
5. Reinstall the plunger lube hoses, discharge piping connections, and suction piping connections.
6. Reinstall the plunger clamps as outlined earlier in “To Change Plungers and Packing”.

NOTE: IF INSTALLING A DIFFERENT SIZE FLUID CYLINDER, A DIFFERENT PLUNGER CLAMP MAY BE
REQUIRED.

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Suction Valve Stop Installation for Grooveless Fluid Ends:

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PLUNGER SIZE STROKE "A" GAP "B"

PUMP (IN.) (IN.) (IN.)
QWS2500 4 ½” – 5 ½” 12 .38

WARNING: USING A SLIDE HAMMER INCORRECTLY CAN RESULT IN INJURY TO HAND OR FINGERS.
WRAP A SUITABLE STRAP AROUND THE SLIDING HAMMER RATHER THAN GRIPPING IT BY HAND.

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Suction Valve Stop Installation for Grooved Fluid Ends:

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SECTION IV: Pump Parts

General Information:
SPM® stocks a large inventory of genuine original equipment replacement parts for each of its pumps. In order
to expedite a parts order and avoid any delays, please provide the following information with your order:
1. The part number and description (refer to drawings and parts lists in this section) of each item ordered.
2. The quantity of each part, kit, or assembly ordered.
3. The model number and serial number of the pump (see identification tags on the fluid end and power
end).
4. Your purchase order number.
5. Specify method of shipment, complete shipping address, complete billing address and telephone
number at the destination of the shipment.

Parts and service may be ordered through the locations listed on the following page, as well as the Weir Oil &
Gas web page at www.weiroilandgas.com:

There is a 25 percent restocking charge for any returned, undamaged parts. Returned parts must include a
SPM® issued “Return Authorization Number” on the shipping label and packing list. Parts must be returned
within 90 days of the original shipping date. Returned parts must be shipped prepaid, to the appropriate
address, including a copy of the original invoice or delivery ticket.

Weir Oil & Gas

601 Weir Way Tel: (817) 246 2461

Fort Worth Fax (817) 246 6324
TX 76108
USA www.weiroilandgas.com

Copyright © 2014, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information
in this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any
purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON,
SAFETY HAMMER, SUR-DROP, DESTINY, STAMPEDE, VERIBAND, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow
Control, Inc.. WEIR is a trademark and/or registered trademark of Weir Engineering Services Limited. Certain features of some of the products disclosed in
this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..

49
 www.weiroilandgas.com
www.weirinaction.com
Headquarters:
601 Weir Way | Fort Worth, TX 76108 | Ph: +1-800-342-7458 | Fax: +1-817-977-2508

NORTH AMERICA:
Fort Lupton, CO–Service Center Villahermosa, Mexico–Service Center
Deer Park, TX–Service Center
13055 Weld County Road 8 Bodega 3, Lote 8, Manzana 3
920 Seaco Court
Fort Lupton, CO 80621 Sobre Calle San Lazaro
Deer Park, TX 77536
Ph: +1-303-535-5450 Parque Logistico Industrial, Tobasco
Ph: +1-832-200-6220
Fax: +1-303-535-5455 Villahermosa, Tabasco 86150
Fax: +1-832-200-6227
Ph: +52-993-142-7083
Mid Continent:
Grand Junction, CO–Service Center EUROPE, MIDDLE EAST, AND AFRICA:
Bossier City, LA–Service Center 842 21 ½ Rd., Building A
Aberdeen, Scotland–Service Center
2403 Grimmett Dr. Grand Junction, CO 81505
Badentoy Industrial Park, Portlethen
Shreveport, LA 71107 Ph: +1-970-243-4600
Aberdeen AB12 4YD, Scotland
Ph: +1-318-677-2422 Fax: +1-970-243-8027
Ph: +44-1224-783666
Fax: +1-318-677-5385
Williston, ND–Service Center Fax: +44-1224-784184
Elk City, OK–Service Center 5073 Owans Industrial Park Drive
Dubai, UAE–Service Center
2111 S. Main Williston, ND 58801
Oilfields Supply Center, L.T.D., Building 18
Elk City, OK 73648 Ph: +1-701-572-0776
P.O. Box 1518, Jebel Ali, Dubai, UAE
Ph: +1 580-225-2385 Fax: +1-701-572-0784
Ph: +971-48836-368
Fax: +1 580-225-3402
South and West Texas: Fax: +971-48836-485
Fort Worth, TX–Service Center
Odessa, TX–Service Center ASIA PACIFIC:
7711 Wyatt Drive
2424 E. I-20
Fort Worth, TX 76108 Indonesia–Service Center
Odessa, TX 79766
Ph: +1 817-935-7964 Jl. Mulawarman No.20 RT 20
Ph: +1-432-580-3887
Fax: +1 817-935-7365 Manggar, Balikpapan, Kalimantan Timur
Fax: +1-432-333-1351
Indonesia 76116
Kilgore, TX–Service Center
Pleasanton, TX–Service Center Ph: +62 542 74 6098
1102 State Hwy 31 W
772 HWY 281 South
Kilgore, TX 75662 Singapore–Service Center
Pleasanton, TX 78064
Ph: +1-903-984-8153 15 Tukang Innovation Drive,
Ph: +1-830-569-351
Fax: +1-903-984-8626 Singapore, 618299
Fax: +1-830-569-3643
Ph: +65-6302-0852
Lafayette, LA–Service Center
Canada: Fax: +65-6302-0883
401 S. Bernard Rd.
Broussard, LA 70518 Edmonton, AB, Canada–Service Center Perth, Australia–Service Center
Ph: +1-337-837-3161 4743 97th St. Henderson Service Center
Fax: +1-337-839-1985 Edmonton, AB T6E 5W2 20 Stuart Drive
Ph: +1-780-438-1122 Perth, Western Australia 6166
Searcy, AR–Service Center
Fax: +1-780-437-5218 Ph: +61-8-9410-7500
2211 Taylor Road
Searcy, AR 72143 Grande Prairie, AB, Canada–Service Center Adelaide (AUS)–Service Center
Ph: +1-501-305-3296 8801 99th Street 174 Cormack Road
Fax: +1-501-305-3419 Clairmont, Alberta T0H 0W0 Wingfield
Ph: +1-780-567-3857 Adelaide, SA, 5013
Northeast:
Fax: +1-780-567-2808 Ph: +61-8-8285-3133
Buckhannon, WV–Service Center Fax: +61-7-8285-3151
Medicine Hat, AB, Canada–Service Center
52 Norwins Drive
1202 Dirkson Drive N.E. Chengdu, China- Service Center
Buckhannon, WV 26201
Redcliff, Alberta T0J 2P0 333 No. Xin Gong Road
Ph: +1-304-472-9701
Ph: +1-403-504-8353 Xin Du, Cheng Du
Fax: +1-304- 472-9130
Fax: +1-403-504-8370 Si Chuan, China 610500
Williamsport, PA–Service Center Ph: +86-28-83924721
Red Deer, AB, Canada–Service Center
76 Odell Road Fax: +86-28-83924722
Unit A, 8060 Edgar Industrial Crescent
Muncy, PA 17756
Red Deer, Alberta T4P 3R3 MANUFACTURING:
Ph: +1-570-546-1005
Ph: +1-403-341-3410
Fax: +1-570-546-2033 Novatech
Fax: +1-403-341-3072
8388 C.F. Hawn Freeway
LATIN AMERICA: Dallas, TX 75217
Rockies:
Ph: +1-214-398-1491
Macae, Brazil–Service Center
Denver, CO–Sales Office
Rua Internacional, No 245,
950 S. Cherry Street, Suite 312
Granja dos Cavaleiros
Denver, CO 80246
Macae, RJ Brazil
Ph: +1-303-535-5450
Ph: +55-22-2106-8750
Fax: +1-303-535-5455
Fax: +55-22-2106-8777

Updated: 1/12/16
Document P/N: 2P136539
Release Date: 12/27/2011
Revision: E

Fluid End Drawings:

51
 8 7 6 5 4 3 2 1
REVISIONS
FLAG NOTES: (SEE PREVIOUS REVISIONS FOR APPROVAL HISTORY)

REV DESCRIPTION DATE PROCESSED BY:

1. WIPER RING SHOWN INSTALLED FOR A LOW
PRESSURE OIL LUBE SYSTEM. FOR HIGH PRESSURE
GREASE APPLICATIONS REVERSE DIRECTION OF WIPER.

D D
Thursday, April 09, 2015 2:20:33 PM

1 1

C C

PACKING NUT FLUID CYLINDER

SIDE 4.50 5.50 SIDE

B A B

4 3 SECTION A-A 2

4 1 4P100651 MACH/LANTERN RING/4.50" 1.409

3 1 4P107775 MACHINING, ADAPTER, 4.50" 2.596
2 1 4P100649 MACHINING, SPACER, 4.50" 1.197
1 1 P139796 ASSY/PKG/SOFT/HP/EX/4.50" 0.490
ITEM QTY.
NO. REQD PART NUMBER NOMENCLATURE OR DESCRIPTION WT (REF ONLY)

PARTS LIST
Proprietary and Confidential
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES, Copyright © 2015 S.P.M. Flow Control, Inc.
WEIGHTS ARE IN LB. TOLERANCES ARE: APPROVALS DATE S.P.M. Flow Control, Inc. ("The Company") is the owner of the copyright
DECIMALS ANGLES FRACTIONS (CURRENT REVISION) and all confidential information in this drawing. The drawing must not be
copied in whole or in part, in any form or by any means, and the
A .X±.1 ±0.5° ± 1/32"
PREPARED A.Grams 03/18/2015
information in it must not be disclosed to any person, or used for any
purpose other than the specific purpose for which it has been provided,
A
.XX±.01 without the prior written consent of the company.
.XXX±.005 .003 PER INCH TITLE
CHECKED A.Grams 04/14/2015
ALL DIAMETERS CONCENTRIC 125 SURFACE ROUGHNESS
TO .010 UNLESS OTHERWISE ALL MACHINED SURFACES APPROVED B.Wagner 4/14/2015 ASSEMBLY, HARD PACKING
NOTED. HIGH PRESSURE
CAD GENERATED DRAWING DO NOT MANUALLY SCALE OR UPDATE. MATERIAL SEE PART DRAWINGS
BALLOONS REVISION FLAG THIRD ANGLE PROJECTION
EXTREME SERVICE, 4.5"
WEIGHT WEIGHT SHOWN
2A140374

5.692
FOR REF ONLY SHEET DWG NO. REV.
XX ITEM #
X XX SCALE 2:3 SIZE B (17 x 11)
1 OF
1 2A140374 IR
8 7 6 5 4 3 2 1
 8 7 6 5 4 3 2 1

D D
Monday, March 05, 2012 5:27:22 PM

10.00 10.00 10.00 10.00

3.50
7.00

TORQUE TO 460 FT-LBS LUBED

C C
3.00

6.00

1
1
A

4.94

11.79

B B

12.69 55.37
3
2 20 3 20 P19239 7/8-9UNC HHCS x 1.50 Lg, Gr B7 0.4881
5 2 5 P100273 SEAL/OR65070025SEAL CVR & SUC MAN 0.05373
1 1 2P117315 MACH, MAN, SUC, ZOOMIE, QUINT, 10" CTC SEE PART DRAWINGS 211.850
ITEM QTY.
PART NUMBER NOMENCLATURE OR DESCRIPTION MATERIAL WT
NO. REQD
PARTS LIST
Proprietary and Confidential
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES, Copyright  S.P.M. Flow Control, Inc.
WEIGHTS ARE IN LB. TOLERANCES ARE: APPROVALS DATE SPM Flow Control, Ltd. ("The Company") is the owner of the copyright
DECIMALS ANGLES FRACTIONS (CURRENT REVISION) and all confidential information in this drawing. The drawing must not be
copied in whole or in part, in any form or by any means, and the
A .X±.1 ±0.5° ± 1/32"
PREPARED J.Pavlicek 11/11/2011
information in it must not be disclosed to any person, or used for any
purpose other than the specific purpose for which it has been provided,
A
.XX±.01 without the prior written consent of the company.
.XXX±.005 .003 PER INCH TITLE
CHECKED J.Marquez 02/29/2012
ALL DIAMETERS CONCENTRIC 125 SURFACE ROUGHNESS
TO .010 UNLESS OTHERWISE ALL MACHINED SURFACES ENGINEER M.Dille 3/5/2012 INSTALLATION, MANIFOLD
NOTED. QWS, 10" CTC
CAD GENERATED DRAWING DO NOT MANUALLY SCALE OR UPDATE. MATERIAL SEE PART DRAWINGS
BALLOONS REVISION FLAG THIRD ANGLE PROJECTION
ZOOMIE, 6" VIC, 3-207 CLEANOUTS
DETAIL A WEIGHT WEIGHT SHOWN
2A117320

221.879 FOR REF ONLY SHEET DWG NO.

SCALE 1 : 2 XX ITEM #
REV.
XX QTY X XX SCALE 1:6 SIZE B (17 x 11)
1 OF
1 2A117320 IR
8 7 6 5 4 3 2 1
SPM®
Well Service Pumps & Flow Control Products

QWS2500 SD Well Service Plunger Pump Power End

Operation Instruction and Service Manual

Document P/N: 2P121267

Release Date: 01/15/2015
Revision: E

Copyright © 2014, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information
in this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any
purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON,
SAFETY HAMMER, SUR-DROP, DESTINY, STAMPEDE, VERIBAND, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow
Control, Inc.. WEIR is a trademark and/or registered trademark of Weir Engineering Services Limited. Certain features of some of the products disclosed in
this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..
Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL

GENERAL INFORMATION

INSTALLATION AND OPERATION

MAINTENANCE AND REPAIR

SALES AND SUPPORT

NOTE

CAUTION

WARNING/ DANGER

2
 Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

SPM® PRODUCT SAFETY GUIDE FOR WELL SERVICE PUMPS

Most SPM® products generate, control or direct pressurized fluids; therefore, it is critical that those who work
with these products be thoroughly trained in their proper application and safe handling. It is also critical that
these products be used and maintained properly!

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “WELL SERVICE PLUNGER PUMP SERVICE MANUAL” THOROUGHLY. TRAINING
IN THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND MAINTENANCE PERSONNEL.
FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE, PROPERTY DAMAGE
OR DAMAGE TO THE ENVIRONMENT.

WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER PRESSURE

CAN CAUSE SERIOUS INJURY OR DEATH.

The following information is given in good faith and should aid in the safe use of your SPM® products. This
information is not meant to replace existing Company's safety policies or practices.

Hot Surfaces: A SPM® well service pump is capable of pumping fluids with temperatures up to 79°C/175°F with
normal trim. The power end of the pump can also be operated at temperatures up to 79°C/175°F. It is the
responsibility of the packager to provide adequate guarding around the fluid end as well as the inlet and
discharge piping to protect against burn injury.

A SPM® well service pump operates at very high pressure and features some external moving parts. It is the
customer's responsibility to provide adequate warning and protection for personnel for when the unit is
operated.

All images and drawings shown in this document are for representation and illustration purposes only. They do
not reflect the actual part/component.

The bill of materials and part numbers in this document can change without notification. For details contact
Weir Oil & Gas.

Personal Responsibilities:
1. When working on the pump, safety glasses, approved safety shoes and hard hat must be worn. Fall
prevention and protection should be in place when working on the pump in raised areas. Surfaces can
become slippery when servicing the pump. Hammering on any part or component may cause foreign
material or steel pieces to become airborne.

2. Personnel should only hammer on the SPM® hammer wrench provided and never directly on the pump
itself. Fractures can occur from repeated misuse. Only soft-type hammers should be used.

3. Personnel should never hammer on one of the valve retainer nuts or any other pump components when
pressure is present.

4. When servicing the pump, do not manually lift any part in excess of 40 lbs. A lift device must be used
in these cases. For parts weighting 40 lbs. or less, proper leg type lifts are essential. Do not lift with a
back type lift.

3
 Document P/N: 2P121267
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Revision: E

5. It is a personal responsibility to use the proper tool when servicing the pump. Any special tools required
are furnished with the pump when new, and should be kept with the pump for its routine maintenance.
It is a personal responsibility to be knowledgeable and trained in the use and proper handling of these
tools for all maintenance of the pump. A pump is made up of internal and external moving parts. All
personnel should be located away from the pump while in operation. Only trained personnel should be
around the pump, especially during service or operation.

On Location:

1. Each pump is clearly marked with a maximum pressure and temperature rating. This pressure must not
be exceeded or SERIOUS INJURY OR DEATH CAN OCCUR.

2. Each pump is clearly marked with a maximum horsepower rating. This horsepower rating should not
be exceeded or mechanical damage can occur, leading to SERIOUS INJURY OR DEATH.

3. The pump's discharge connections should be properly cleaned and lightly oiled before the downstream
piping is attached. Any worn, damaged or missing seals should be replaced before engaging the
pump's drive.

4. The pump's suction connections should be properly cleaned and lightly oiled before the supercharge
hoses are attached. Any worn, damaged or missing seals should be replaced prior to pumping. Leaking
connections can cause pump cavitation leading to equipment failure and subsequent INJURY OR
DEATH.

5. Any fluid cylinder which has been pressured beyond its specified working pressure should be returned
to Weir Oil & Gas for disassembly, inspection and recertification.

6. Welding, brazing or heating any part of the pump, with the exception of driveline companion flanges, is
prohibited. If accessories must be attached, consult Weir Oil & Gas factory prior to installation.

7. The SPM® pump suction supply flow and pressure minimums in the pump service manual must be
maintained or equipment damage will occur and can lead to SERIOUS INJURY OR DEATH.

8. A complete visual inspection of the pump's power end and fluid end must be made prior to each use.
Any leaking seals, broken bolts, leaking hoses or improperly tightened parts must be remedied prior to
rotating the pump.

9. Any oil and other contaminants from pump should be contained during operation and throughout the
maintenance process. Improper containment can lead to serious injury, equipment damage, property
damage, or damage to the environment.

10. If a pump is used in a place where permanent piping is to be attached, frame flexing or structure
movements must be considered. Do not place the discharge or suction connections in a bind. Inspect
all components of such piping structure, including any valves, every 90 days for wash, erosion,
corrosion, etc. Replace if worn. For mobile mounted units; discharge line swivels are required.

11. SPM® well service pumps are to be installed and operated in a horizontal position only, as shown in the
pump's service manual. Operation in an extreme inclined position could cause equipment failure,
leading to injuries due to improper oil flow and/or improperly sealing valves.

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Revision: E

12. Any repairs or service (even routine maintenance) performed on the pump must be performed by a
trained service technician who is qualified to work on high pressure reciprocating plunger pumps. All
such service and repairs must be supervised by qualified management personnel or returned to Weir Oil
& Gas for service. Only SPM® replacement parts should be utilized. Failure to do so may result in loss of
warranty as well as SERIOUS INJURY OR DEATH. Weir Oil & Gas provides a Pump Maintenance
Mechanic Training School to qualify pump service mechanics.

13. SPM® well service pumps should never be used to pump gaseous, explosive or uninhibited corrosive
fluids. These may result in equipment failure, leading to INJURY OR DEATH.

14. Never place hands in the area of reciprocating pony rods or plunger paths. If work must be done in this
area, make sure pump is disengaged from driver and isolated from suction and discharge pressure prior
to initiating activity (locked out and tagged out).

Special Precautions:

1. The modifications to or unauthorized repair of any part of an SPM® pump, or use of components not
qualified by SPM®, can lead to pump damage or failure and SERIOUS INJURY OR DEATH.

2. The pump's fluid end and related piping must always be flushed with clean water after every job. If
freezing temperatures are anticipated the fluid cylinder must be completely drained of any fluid. Failure
to do this may result in fluid cylinder damage from fluids which have hardened or frozen.

3. All SPM® threaded components are right hand threaded unless specifically designated otherwise.
Turning counterclockwise will loosen the assembly. Always make sure any threaded connection is made
up properly with the proper torque.

4. All products should be properly cleaned, greased or oiled after each use and inspected prior to each use.
Do not put oil on the valve seat or fluid end valve seat tapered area.

5. Pressure seal (line pipe) threads are not recommended for pulsating service above 10,000 psi or where
side loading or erosion are suspected. Non-pressure seal (round tubing) threads or straight integral
connections are recommended under these conditions. In order to achieve the recommended Non-
Shock Cold Working Pressure, power-tight make-up is required on threaded connections. Consult the
factory for any usage other than normal constant flow working conditions. Integral connections are
recommended in lieu of pipe threaded connections for all pump applications.

6. Each integral union connection is clearly marked with a pressure code (i.e. “1502”, 15,000 psi). This
pressure must not be exceeded. This code should also be used with mating unions. Improper mating
can result in failures. All integral union connections used must match (according to size, pressure
rating, etc.). These connections must also match the service of the designated string they are installed
in.

5
 Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

Inspection & Testing:

1. Each pump, its drive system, and its fluid piping should be visually checked each time before operating.
All worn, damaged or missing parts should be remedied before starting the pump.

2. All fluid cylinder mounting nuts must be checked routinely with a certified torque wrench. Loose fluid
cylinder mounting nuts can cause the fluid end to separate from the power end resulting in SERIOUS
INJURY OR DEATH.

3. All studs and stay rods require tightening to the proper torque. Without proper torque, the fluid end
will "breathe" or flex against the power end resulting in stud failure, stay rod failure and/or even
premature fatigue failure in the power or fluid end. Consult Weir Oil & Gas for torque information (see
assembly drawings for torque values).

4. All covers must be tight and properly torqued. Otherwise, premature fatigue and possible fluid end or
component failure can result.

5. All fluid ends must be disassembled and dimensionally inspected routinely. Any fluid cylinder or
discharge flanges which exhibits any loss in wall thickness due to washing or corrosion pitting in any
area must be returned to Weir Oil & Gas for repair and recertification prior to operating again.

6. All fluid cylinders in operation must be disassembled and inspected for cracks. Fluid cylinder inspection
should occur on a monthly basis or every 100 hours of operation. The operation of any pump with even
small surface cracks in any area of the fluid cylinder can result in equipment failure and SERIOUS INJURY
OR DEATH.

7. All fluid cylinders should be hydrostatically tested at least twice each year by a qualified technician.
Prior to any pressure testing, all air must be evacuated from the system. Failure to do so could result in
PERSONAL INJURY OR DEATH. The maximum test pressure must not exceed the equipment's rated
working pressure. The hydrostatic pressure test must be followed with an ultraviolet light/magnetic
particle inspection of the internal bores prior to reinstalling and operating under pressure.

6
 Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

TABLE OF CONTENTS

SECTION I: GENERAL INFORMATION ............................................................................................................. 8

USEFUL PUMP DATA FORMULAS: ........................................................................................................................ 8
SHIPPING AND STORAGE: ................................................................................................................................ 10
SECTION II: INSTALLATION AND OPERATION .............................................................................................. 11
SPM® QWS2500 SD PUMP DESCRIPTION: ....................................................................................................... 11
PERFORMANCE DATA: ..................................................................................................................................... 13
INSTALLATION HIGHLIGHTS:............................................................................................................................. 25
LIFTING REQUIREMENTS: ................................................................................................................................. 26
COMPANION FLANGE INSTALLATION: ................................................................................................................ 27
RECOMMENDED POWER END LUBE OILS: ........................................................................................................... 30
POWER END LUBE SYSTEM REQUIREMENTS: ........................................................................................................ 31
POWER END LUBE SYSTEM SCHEMATIC: ............................................................................................................. 34
POWER END LUBE STARTUP AND PERFORMANCE DATA:......................................................................................... 34
TACH DRIVE/RATE METER CALIBRATION SPECIFICATIONS: ...................................................................................... 37
STARTUP AND BREAK-IN PROCEDURE: ................................................................................................................ 38
SECTION III: MAINTENANCE AND REPAIR .................................................................................................... 42
ROUTINE PREVENTATIVE MAINTENANCE: ............................................................................................................ 42
TROUBLESHOOTING GUIDE: ............................................................................................................................. 44
SPM® QWS2500 SD DURALAST™ FLUID END REMOVAL: .................................................................................... 46
SPM® QWS2500 SD GROOVED AND GROOVELESS FLUID END REMOVAL: .............................................................. 47
SPM® QWS2500 SD POWER END REPAIR PROCEDURES:...................................................................................... 48
SECTION IV: PUMP PARTS ............................................................................................................................ 49
GENERAL INFORMATION:................................................................................................................................. 49
WEIR OIL & GAS LOCATIONS:.......................................................................................................................... 50
POWER END DRAWINGS: ................................................................................................................................. 51

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SECTION I: General Information

Useful Pump Data Formulas:
Definition of Symbols Used:
A - Area (sq. in.)
BHP -Brake horsepower
BPM -Barrels per minute (U.S.)
FV -Flow velocity (ft./sec.)
GPM -Gallons per minute (U.S.)
GPR -Gallons per revolution (U.S.)
HHP -Hydraulic horsepower
ID -Inside diameter (inches)
ME -Mechanical efficiency
NC -Number of cylinders (per pump)
PD -Plunger diameter (inches)
PSI – Pressure (lbs./sq./in.)
RL -Rod load (lbs.)
RPM -Crankshaft revolutions per minute
SL -Stroke length (inches)
T -Torque (ft. lbs.)

Useful Pump Data Formulas:

 To calculate the HHP output when the volume and pressure are known:

GPM x PSI = HHP

1714

 To calculate the BHP input required when the volume, pressure, and mechanical efficiency are known:

GPM x PSI = BHP

(1714 x ME)

 To calculate the maximum possible pressure when the BHP, GPM, and ME are known:

BHP x (1714 x ME) = PSI

GPM

 To calculate the maximum possible GPM when the BHP, PSI, and ME are known:

BHP x (1714 x ME) = GPM

PSI

 To calculate rod load when the plunger diameter and pressure are known:

PD x PD x .7854 x PSI = RL

 To calculate the maximum possible pressure at a given rod load when the RL rating and plunger
diameter are known:

RL = PSI
PD x PD x .7854
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 To calculate the GPR flow in gal/rev or GPM when the plunger diameter, stroke length, and number of
cylinders is known:

PD x PD x .7854 x SL x NC = GPR
231

GPR x RPM = GPM

 To calculate the fluid flow velocity through a pipe or hose when the GPM and pipe size are known:

Pipe I.D. x Pipe I.D. x .7854 = Internal Area = A

GPM x .3208 = (FV) Flow Velocity

A

 To calculate the size pipe of hose required to maintain a specified flow velocity when the GPM and
desired flow velocity are known:

GPM x .3208 = Internal Area Required

FV

 To calculate the maximum allowable GPM through a specified hose or pipe at a specified flow velocity
when the internal area of the pipe and the desired flow velocity are known:

FV x A = Max GPM
.3208

 To calculate pinion shaft or driveline torque when the input BHP and pinion shaft RPM are known:

BHP x 5252 = Torque

Pinion Shaft RPM

Conversion Factors:

Multiply: By: To Obtain:

Barrels (U.S.) 42 Gallons (U.S.)
Gallons (U.S.) .023809 Barrels (U.S.)
Gallons (U.S.) 231 Cubic Inches
Cubic Inches .004329 Gallons (U.S.)
Cu. Ft./Sec. 448.831 GPM
GPM .002228 Cu. Ft./Sec.
Head Feet (water) .4334 PSI
PSI 2.307 Head Feet (water)
Kilowatts 1.341 Horsepower
Horsepower .7457 Kilowatts

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Shipping and Storage:

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE, OR MAINTAIN THIS WELL SERVICE PUMP
WITHOUT READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGLY. TRAINING
WITH THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND MAINTENANCE
PERSONNEL. FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE,
PROPERTY DAMAGE, OR DAMAGE TO THE ENVIRONMENT.

All SPM® pumps are shipped dry and must be flushed and filled with the proper lubricant before operating
(refer to Installation and Operation Section). Pumps may be flushed with diesel oil or light oil. When pumps
are shipped by ocean cargo, care should be taken to crate the pump in a watertight container and ship below
deck to prevent salt-water contamination.

New pumps are not prepared for long periods of storage and should be put in service as soon as possible. To
prepare a pump for storage after prior use, clean the fluid end and flush it with good rust preventive. Plug all
fluid end discharge and suction openings. Drain oil from power end, thoroughly clean and flush with a good
rust preventive, which will not clog oil passages. Remove crankcase breather and plug all openings. Coat the
pinion extensions and pony rods with a heavy rust preventive. Store pump inside in a warm, dry place.

CAUTION: PUMPS THAT HAVE BEEN SITTING IDLE FOR ANY APPRECIABLE PERIOD OF TIME (TWO
WEEKS OR MORE) MUST HAVE THE PLUNGERS AND VALVES REMOVED, COATED WITH A LIGHT
LUBRICANT AND REINSTALLED PRIOR TO OPERATING. THE ELASTOMERIC PLUNGER PACKING AND
VALVE INSERTS WILL STICK TO THE MATCHING METAL PARTS AND BECOME DAMAGED UPON
STARTUP IF NOT DISASSEMBLED AND LUBRICATED FIRST.

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SECTION II: Installation and Operation

SPM® QWS2500 SD Pump Description:

The SPM® QWS2500 SD is a reciprocating, positive displacement; horizontal single-acting, quintuplex plunger
pump which is rated at 2500 Brake Horsepower, input maximum. The SPM® QWS2500 SD is designed for
intermittent duty well service applications such as acidizing, fracturing, well killing, etc.

The SPM® QWS2500 SD Pump consists of a Power End Assembly and a Fluid End Assembly. Nine different fluid
cylinders are available to accommodate nine different plunger sizes for a variety of pressures and volumes.

Optional packing assemblies, valve assemblies, discharge flanges, suction manifolds, etc. are available for a
wide variety of unitization arrangements, for the pumping of various specific fluids, and for service in a wide
range of ambient conditions. The weight of the pump will vary slightly depending on plunger size and other
options, but will not vary more than plus or minus 5% of the advertised weight.

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The SPM® QWS2500 SD power end design and construction details are as follows:

Housing
Fabricated steel/stress relieved, line bored.

Crankshaft
Machined from heat treated steel. Precision ground journals. Supported by six heavy-duty cylindrical main
roller bearings.

Bull Gears
Double opposing helical type gears. High horsepower AGMA #10 quality. Precision machined from high
strength alloy steel. Induction hardened gear teeth. Rigidly supported on both ends by crankshaft extension.

Pinion Shaft
Double opposing helical type gears integrally machined on heat-treated alloy steel shaft. High horsepower
AGMA #12 quality. Induction hardened gear teeth. Supported by two (2) heavy-duty spherical roller bearings.

Gear Ratio
6.353:1 ratio allows direct drive from a 1900 to 2100 RPM diesel engine/powershift transmission without over-
speeding the pump.

Pony Rods
Replaceable type w/clamp connection at plunger end. Machined from steel. Precision ground hard overlay
seal surface.

Stay Rods
Precision machined from high strength heat-treated alloy steel.

Connecting Rods
Precision machined from high strength, ion nitrided steel forgings.

Crossheads
Precision machined from high strength steel full-cylindrical casting.

Crosshead Guides
Replaceable, full-cylindrical design. Precision machined from bronze casting.

Wrist Pins
Precision machined from heat-treated steel.

Lubrication
Equipped for pressurized lubrication to all moving parts. “Dry Sump” type system.

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Performance Data:

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Installation Highlights:

The proper installation of your SPM® well service pump is a must in obtaining long life and trouble free service.
Particular attention must be given to the following items:

Power Source:
The prime mover (usually a 1900 to 2100 RPM diesel engine) should be rated at no more than 2700 BHP
intermittent service in order to avoid overpowering the pump.

Drivetrain:
The drivetrain which connects the pump to the engine should include a transmission (7 speed or more) and a
mechanical driveline with universal joints and a slip joint in order to fully utilize the pump's wide range of
pressure and flow capabilities.

A powershift type transmission with integral torque converter and automatic lock-up clutch will provide the
most trouble-free means of shifting under pressure. When using any transmission with a “high gear” or
“overdrive” ratio greater than 1.0:1, the “overdrive” gear range must be blocked out in order to avoid
overspeeding the pump. Extreme caution should be exercised in order to avoid over-pressuring the pump
when operating in low gear or converter mode.

The mechanical driveline should have a “Diesel Engine Use” torque rating of 20,000 ft. lbs. (96,000 ft. lbs.
Short Duration) and should have no less than 1” slip capacity. Weir Oil and Gas recommends a maximum
driveline angle of 3 degrees.

Power End Mounting:

The pump must be securely bolted to the skid or vehicle at all four power end mounting hold locations (Refer
to pump installation drawing).

Power End Lubrication:

SPM® well service plunger pumps are shipped dry, do not include an integral oil pump, and are designed for a
pressure lubricated dry sump system. An auxiliary oil reservoir and engine driven oil pump must be provided for
proper lubrication. More information pertaining to the power end lube system and power end lube oils is
included in this manual on page 30.

Plunger Lubrication:
SPM® well service plunger pumps require a force fed oil base plunger lube system. More information pertaining
to the plunger lube system and plunger lube oils is included in the fluid end manual.

Supercharging System:
SPM® well service plunger pumps require the use of a centrifugal slurry pump supercharging system to avoid
cavitation at the higher pump speeds. More information pertaining to the supercharging requirements is
included in this manual.

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Lifting Requirements:
The fully assembled SPM® QWS2500 SD weighs approximately 15,200 lbs. (67.6KN) dry, with a standard fluid
end and suction manifold.

The SPM® QWS2500 SD power end weighs approximately 10270 lbs. (45.7KN) dry.

CAUTION: DO NOT MOUNT THE PUMP ON AN INCLINE OR VERTICALLY.

WARNING: LIFTING THE SPM® QWS2500 SD PUMP OR QWS2500 SD FLUID END ASSEMBLY WITHOUT
USING EQUIPMENT RATED FOR THIS LOAD CAN CAUSE EQUIPMENT DAMAGE, PERSONAL INJURY OR
DEATH.

WARNING: DO NOT HANDLE, LIFT, INSTALL, OPERATE OR MAINTAIN THIS SPM® PUMP WITHOUT
READING THIS “OPERATION INSTRUCTION AND SERVICE MANUAL” THOROUGHLY. TRAINING IN
THESE DOCUMENTS IS A MUST FOR PACKAGERS, OPERATIONS, AND MAINTENANCE PERSONNEL.
FAILURE TO DO SO CAN LEAD TO SERIOUS INJURY, DEATH, EQUIPMENT DAMAGE, PROPERTY DAMAGE
OR DAMAGE TO THE ENVIRONMENT.

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Companion Flange Installation:

Weir Oil & Gas provides the SPM® QWS2500 SD pump with one of three options:

 Keyed companion flange installed on the pinion.

 Splined companion flange installed on the pinion.
 No companion flange installed on the pinion.

The companion flange is heated prior to installation due to the interference fit on the pinion. During the flange
installation on the pinion shaft the customer must prevent excessive heat transfer from damaging the pinion
seal. If cooling is not provided immediately after mounting the flange, then the heat will be transferred rapidly
from the flange to the pinion seal. This can distort or melt the seal lips, leading to failure and leakage of oil. The
following are the proper steps for flange installation without damaging the seal (Fig 1 & 2 on next pages).

Wear protective clothing; provide good drainage, and a secure work location when performing this operation.

1. Thoroughly clean all mating surfaces of both the flange and the pinion shaft; ensuring that the faces are
free of debris and damage that might impede smooth installation. Remove any burrs or corrosion.
2. Lubricate the mating surfaces with suitable grease.
3. Access to a pressured water hose connection should be available.
4. Using good practices, carefully heat the companion flange evenly to 1210C/2500 F.
5. While flange is hot; mount the drive hub onto the pinion, ensuring full engagement.
6. Flood the companion flange-dampener adapter assembly with cool water. Pay particular attention to
the backside of the hub that is closest to the seal housing.
7. Finish securing the hub by continuing to provide water until thoroughly cooled.

As metal - to - metal contact is a good conductor of heat; time is of the essence during flange installation.
Decrease dwell time and provide plenty of water to reduce the rapid transfer of heat. This will protect the
pinion seal and prevent potential leakage.

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Recommended Power End Lube Oils:

Selecting the proper gear oil for satisfactory power end lubrication is very important to obtaining long life and
trouble-free service from the high performance SPM® plunger pump. Weir Oil & Gas highly recommends the
use of one of the modern “synthetic” gear lubricants, which are now available through all major lubricant
marketers. Synthetic lubricants exhibit a much more stable viscosity over a wide range of ambient temperature
conditions. Synthetics also offer a much improved film strength compared to a conventional gear oil of the
same viscosity. The use of synthetic gear lubricants will improve lubricant flow at pump startup, will provide
superior wear protection, and will result in higher “hydraulic horsepower” output due to reduced drag and
friction between mating parts.

NOTE: TO OBTAIN OPTIMUM PERFORMANCE, REGARDLESS OF THE POWER END LUBRICANT SELECTED,
THE LUBRICANT TARGET OPERATING TEMPERATURE SHALL STAY BELOW 175° F (79° C)

General Service Power End Lubricant:

Gear oil must have the following properties:

1. Viscosity rating of ISO 220
2. Rated for extreme pressure (EP) service
3. Viscosity Index of 100 or higher
4. Pour Point of 0° F (-17.70 C)or lower
5. Timken Test rating of 50 lbs. or higher

Cold Temperature Service Power End Lubricant:

Weir Oil & Gas highly recommends the use of an extreme pressure gear oil for any plunger pump being used in
a cold temperature environment for ambient conditions frequently below 320 F (00 C). For environments with
extreme temperature shifts between seasons, it is recommended to switch from General Service to Cold
Temperature Service oils based on normal ambient temperatures.
Cold Temperature Service oils must have the following properties:
1. Viscosity rating of ISO 150
2. Rated for extreme pressure (EP) service
3. Viscosity Index of 100 or higher
4. Pour Point” of –20° F (-28.80 C) or lower
5. Timken Test rating of 50 lbs. higher

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Power End Lube System Requirements:

Providing a well-designed trouble-free power end lube system is one of the most important factors in obtaining
maximum service and long life from the SPM® QWS2500 SD Well Service Plunger Pump. Due to the nature of
well servicing operations, the highest pump pressures and highest load conditions typically occur at very slow
pump speeds. This characteristic of well service pump operation necessitates the use of an engine driven lube
pump that will deliver maximum lube oil volume at high engine speeds regardless of slow pump speeds. As a
result of this operating characteristic and the many different equipment design possibilities, it is not feasible for
SPM® to provide a power end lube system with the pump. The equipment manufacturer who builds the
powered well service unit must provide power end lube system components that are compatible with the
specific engine, transmission, etc. being utilized on the unit.

A properly designed power end lube system will meet the following specifications:

1. Oil Reservoir:
A. Must be of 100 gallon capacity, minimum.
B. Suction outlet to be 3” minimum and located as deep as possible.
C. Suction outlet and return inlets to be as far apart as possible.
D. Return fitting for drain line(s) back to tank to be 3” minimum; return fitting for relief valve line to
be 1” minimum.
E. A serviceable magnet located near the 3” return port is highly recommended.
F. Breather/filler cap to be 40 micron/25CFM minimum and should include a built-in strainer to
prevent trash from entering the reservoir.
G. Sight glass (preferred) or dipstick to indicate oil level in the reservoir.
H. Reservoir must be located below the lowest drain port in the plunger pump and as near the
plunger pump as possible (preferably directly underneath).
I. A small air space should be designed into the tank. (See power end lube startup and performance
data)
J. A removable cover to allow access to the tank for clean out will assist in preventative maintenance.

2. Lube System Suction Piping:

A. Must be 3” I.D. minimum throughout so that the suction flow velocity never exceeds 2 to 3 ft. per
second.
B. Must include a suction strainer w/3” minimum port size, 40 to 100 mesh (400-150 micron) wire
cloth, 1500 sq. in. minimum element area, 3 to 5 PSI (6 to 10 Hg) built-in bypass, and rated at 150
GPM minimum flow. An in-line wye type strainer is much preferred due to the ease of routine
maintenance in cleaning the element.
C. A 3” minimum swing type check valve may be used in the suction line if the lube pump is located
above the fluid level in the reservoir.
D. The suction line should be as short as possible, should be free from excessive bends, and should be
wire reinforced to prevent collapsing. If longer than 10 ft. the resulting friction losses should be
compensated for by increasing the line size above 3” I.D.

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3. Lube Pump:
A. Must be a gear type pump rated at 50 GPM minimum at its installed maximum RPM.
B. Inlet and outlet ports should be as large as possible w/1½” inlet and 3/4” outlet preferred.

NOTE: IF THE GEAR PUMP SUCTION INLET PORT IS SMALLER THAN 1 ½”, A SWAGE CONNECTION
SHOULD BE USED ON THE SUCTION PORT IN ORDER TO MAINTAIN A 3” SUCTION LINE SIZE AS NEAR
THE GEAR PUMP AS POSSIBLE.

C. A liquid filled vacuum gauge (0 to 30” Hg) should be installed as near the gear pump suction port
as possible in order to monitor the suction flow conditions, especially during cold startups in cold
weather.
D. The gear pump may be direct coupled to an accessory drive location on the engine or can be direct
coupled to the transmission with a pump-mount type power take-off (PTO). The transmission/PTO
mount usually offers the advantage of a lower mounting and improved suction conditions. The
lube pump mounting must be a direct coupled positive drive arrangement which operates at
engine speed whenever the plunger pump's prime mover is running.

4. Lube System Pressure Lines and Oil Filter:

A. The oil filtration system should target an ISO 16/14/11 standard of cleanliness.
B. Pressure lines must be 1 ¼” I.D. minimum in order to maintain a flow a velocity of 10 to 12 ft. per
second maximum.
C. Pressure lines should be wire reinforced with a minimum working pressure of 800 PSI.
D. The oil filter must be rated at 150 GPM/200 PSI minimum, must have a built-in 40 PSI minimum
relief valve, and 25 to 33 micron elements. The filter should be a canister enclosed throw-away
element type; the Parker 60 series filter is widely used and accepted. The filter must be located in
an easily serviceable location and a built-in bypass indicator (service indicator) is recommended. A
dual element filter rated at more than 150 GPM will decrease the pressure drop associated with
filtering the power end oil and will increase the time interval required between filter element
changes. An external relief valve should never be used to protect the filter.
E. A liquid filled 0 to 200 PSI oil pressure gauge must be located at the 1” NPT lube inlet on the
plunger pump. An auxiliary oil pressure gauge is also highly recommended for those units having
remote control consoles.

5. Lube System Relief Valve and Relief Return Line:

A. The system relief valve should be a 1” 30 to 45 GPM, 60 PSI minimum/200 maximum, adjustable
non-chattering type relief valve.
B. The relief valve should be located at the plunger pump's 1” NPT lube port opposite the lube inlet
to insure oil flow throughout the plunger pump before reaching the relief valve.
C. The relief return line should be 1” I.D. minimum, wire reinforced, rated at 800 PSI minimum
operating pressure; and should return directly to the reservoir. The return line port should be
opposite the suction line outlet port on the power end lube tank.

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6. Lube Drain Lines (from plunger pump to reservoir):

A. The SPM® QWS2500 SD is equipped with 3” or 4” NPT drain ports in the bottom of the power end
housing. The drain lines should never be smaller than the drain port in the power end and should
be as short as possible. The drain lines should be free of excessive bends and kinks and should flow
continuously downhill to the reservoir.
B. A 0 to 250F oil temperature gauge should be installed in the primary drain line such that its sensor
will be submerged in the return oil from the plunger pump. The temperature gauge should also be
located in a place easily accessible for viewing. An auxiliary oil temperature gauge is also highly
recommended for those units that have a remote control console.

7. Oil Cooler
A. In extremely hot ambient conditions, an oil cooler may be required to prevent excessive oil
temperatures and inadequate oil viscosity. When used, the oil cooler should be of the “air to oil” or
“forced air” type and should be located down-stream from the oil filter. The cooler should be rated
at 80 GPM/300 PSI minimum, and should have 2” minimum inlet and outlet connections. If the
well service unit will also be subjected to periods of cold weather, the oil cooler must be plumbed
in a manner that will allow the oil to bypass the cooler when cold ambient conditions occur.
8. Oil Heater
A. In extremely cold ambient conditions, the use of either an electric sump heater or a “tube and
shell” heat exchanger may be required to prevent poor lube suction oil conditions, lube pump
damage, and plunger pump damage due to the lube oil becoming too cold and viscous to flow
properly. It is suggested that the power end lube oil be preheated prior to operation in these
conditions. When used, the electric sump heater should be installed near the suction outlet in the
oil reservoir and should be capable of heating the oil to approximately 800 F to 1000 F (270 C to 380
C) over an 8 to 12 hour period of time. The sump heater must be thermostat controlled to prevent
overheating the oil.

When using a “tube and shell” type heat exchanger for lube oil heating with engine jacket water,
the heat exchanger should be rated at 80 GPM/300 PSI minimum with 2” minimum inlet and
outlet oil passage connections. The heat exchanger must be plumbed in a manner that will allow it
to be easily bypassed in the event the power end lube oil temperature starts to exceed 1750 F(
790C).

NOTE: UPON REQUEST, WEIR OIL & GAS CAN ASSIST IN PROVIDING LUBE SYSTEM COMPONENTS
THAT MEET OR EXCEED THE SPECIFICATIONS NOTED HEREIN. PLEASE CONTACT THE WEIR OIL & GAS
ENGINEERING DEPT. FOR ANY FURTHER INFORMATION PERTAINING TO YOUR SPECIFIC PUMP
LUBRICATION REQUIREMENTS.

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Power End Lube System Schematic:

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Power End Lube Startup and Performance Data:

A properly designed lube system should require adjustments to the system only - at the well service unit’s
original startup. The following is the SPM® recommended guidelines for making the initial adjustments as
well as the lube system’s operating specifications.

Initial Lube System Adjustments and Specifications

A. Fill the power end lube oil reservoir with the proper grade of ISO EP gear oil for the existing ambient
conditions. Do not over-fill the reservoir - the proper oil level should always leave approximately 10% air space
above the fluid level. For example, only 90 gallons of oil should be used in a reservoir, which has a 100%
internal capacity of 100 gallons. Disconnect the lube oil suction hose at the lube pump suction inlet and fill the
hose w/gear oil to prime the lube pump. Reinstall and tighten the suction hose.
B. With the plunger pump’s transmission in neutral, start the engine and run at idle only. It will take a few
minutes to pump oil throughout the entire system completely filling all lines, filters, etc. during which time a
thorough check should be made for oil leaks at hose connections, etc. After all the lines are filled, the system
should begin to show pressure on the gauge at the lube inlet of the plunger pump. Let the engine run for five
more minutes to purge the system of air. Stop the engine and add oil to the reservoir in order to bring it back
to the full level.
C. With the transmission in neutral, restart the engine. Rev the engine up to full RPM gradually while
checking both the vacuum gauge at the lube pump suction inlet and the pressure gauge at the plunger pump
lube inlet. If the lube oil is warm enough and thin enough, the vacuum reading should not exceed 10”Hg. If
the oil is too cool and viscous, the engine RPM should be slowed until the vacuum reading falls to 10”Hg. The
oil will eventually warm up just from the friction of traveling through the lube system and through the plunger
pump.

When the vacuum reading no longer exceeds 10”Hg at full engine RPM, adjust the lube system relief valve so
that the lube pressure does not exceed approximately 150 to 175 PSI at full engine RPM.

NOTE: THE OIL FILTER IS USUALLY THE LOWEST PRESSURE RATED COMPONENT IN THE LUBE SYSTEM.
THE SYSTEM RELIEF VALVE SETTING IS MADE PRIMARILY TO PROTECT THE OIL FILTER AND CAN BE A
HIGHER SETTING THAN 175 PSI AS LONG AS IT DOES NOT EXCEED THE LOWEST RATED
COMPONENT IN THE SYSTEM. THE PLUNGER PUMP ITSELF WILL NOT BE DAMAGED UNLESS THE OIL
PRESSURE EXCEEDS APPROXIMATELY 400 PSI.

Again, check the entire lube system for leaks, stop the engine, and add oil to the reservoir if necessary. The
plunger pump should not be rotated until the plunger lube system is operating properly.

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Power End Lube System Operating Specifications

Power end lube system readings will vary considerably due to the extreme viscosity changes in the gear oil as it
warms and thins from a cold startup until it reaches full operating temperature. The system pressure and
vacuum variations are caused by the extreme viscosity changes in the oil. The typical ISO gear oil even at room
temperature is very viscous, creates much resistance to flow in the system, and creates high system pressures
even at very low lube flow rates. Likewise, the typical ISO gear oil at 150F to 175F becomes much less viscous,
flows very freely, and creates much less resistance in the system showing up as considerably lower system
pressures.
Due to the extreme viscosity changes in the gear oil and due to the many different possible system designs, it is
difficult to establish a firm set of system readings which will be highly accurate for every system. Each system
will vary somewhat especially in the area of stabilized temperature and pressure readings during full
horsepower or full torque plunger pump operation. The system specifications herein should be observed in
addition to each unit’s “normal” system characteristics after having been put into service. Extreme deviations
from “normal” in any unit’s system is an important factor in spotting potential problems and avoiding power
end damage due to insufficient lubrication.
 Maximum Acceptable Vacuum Reading at Lube Pump Suction Inlet:
10”Hg (Any Time While Operating the SPM® Plunger Pump)
 Maximum Oil Pressure at Cold Startup and Full Engine RPM:
175 PSI
 Maximum Oil Temperature:
 1750 F / 790 C Approximate Normal Oil Pressure:
70-100 PSI (At Stabilized Operating Temperature and Full Engine RPM)
 Minimum Oil Pressure:
50PSI (At Any Time While Operating the SPM® Plunger Pump at Full Engine RPM and at Stabilized
Operating Temperature)
NOTE: ANY SUDDEN VACUUM, PRESSURE, OR TEMPERATURE DEVIATIONS FROM NORMAL
(ESPECIALLY IF ACCOMPANIED BY ANY UNUSUAL NOISE, VIBRATION, OR SMOKE) INDICATE THE
NEED TO CEASE PUMPING OPERATIONS AND INVESTIGATE THE PROBLEMS BEFORE POWER END
DAMAGE OCCURS. (SEE TROUBLE SHOOTING SECTION OF THIS MANUAL).

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Tach Drive/Rate Meter Calibration Specifications:

PLUNGER * FLUID DISPLACEMENT

DIAMETER INCHES PER TACH DRIVE REVOLUTION PER TACH DRIVE REVOLUTION @ 100%
@ 95% V.E. V.E.
(MM) GPR BPR LPR GPR BPR LPR
3½” (88.9) .2491 .00593 .9429 .2622 .00624 .9926

3¾”(95.3) .2860 .00681 1.0825 .3010 .00717 1.1394

4” (101.6) .3254 .00775 1.2316 .3425 .00816 1.2964

4½ (114.3) .4118 .00981 1.5587 .4335 .01032 1.6408

5” (127.0) .5084 .01211 1.9244 .5352 .01274 2.0257

5½” (139.7) .6152 .01465 2.3285 .6476 .01542 2.4510

5¾” (146.1) .6724 .01601 2.5450 .7078 .01685 2.6789

6” (152.4) .7321 .01743 2.7711 .7707 .01835 2.9169

6½” (165.1) .8592 .02046 3.2522 .9045 .02153 3.4234

NOTE: THE VOLUMETRIC EFFICIENCY AND RESULTING DISPLACEMENT WILL VARY SLIGHTLY DUE TO
OPERATIONAL FACTORS SUCH AS PUMP SPEED, SUPERCHARGE CONDITIONS, AND THE SPECIFIC
GRAVITY OF THE FLUID BEING PUMPED.

V.E. = VOLUMETRIC EFFICIENCY OF PUMP

GPR = U.S. GALLONS PER REVOLUTION
BPR = U.S. BARRELS PER REVOLUTION
LPR = LITER PER REVOLUTION

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Startup and Break-In Procedure:

Each new pump must undergo a brief but thorough startup and break-in procedure in order to verify the field
worthiness of the unitized pumping system and in order to allow a gradual “wearing in” of various mating
parts in the pump itself. The following guidelines have been established by Weir Oil & Gas to minimize startup
problems and ensure maximum service from the plunger pump:

A. Inspection Prior to Starting Engine:

1. Check to see that all masking tape, rust preventative, etc. has been removed from moving parts
such as pony rods, plungers, pinion shaft, etc.
2. Check to see that the plunger pump is securely bolted to the skid or truck frame.
3. Check to see that the driveline is securely fastened to the plunger pump’s input shaft and that
adequate slip is present in the driveline’s slip joint.
4. Check to see that the power end lube oil reservoir has been flushed and drained then filled with
the proper type of gear oil.
5. Check to see that the plunger lube oil reservoir has been flushed and drained then filled with the
proper type of rock drill oil.
6. Check to see that the supercharge piping system has been completely flushed and all piping
connections are tight.
7. Check to see that the power end lube system startup adjustments and plunger lube system
startup adjustments have been performed.
8. Check to see that the suction pulsation dampener has been recharged properly.
9. Check to see that the primary suction piping is connected to an adequate supply of cool clean
water for testing. Check to see that all connections are tight and supply valves open.
10. Check to see that the plunger pump’s discharge piping is safely installed all the way back to the
water reservoir. Check to see that all connections are tight and all valves are open.
11. Follow the engine manufacturer’s recommendations for engine startup and warm-up.

B. Warm-up Procedure Prior to Rotating the Plunger Pump:

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

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C. Plunger Pump Valve Seating Procedure:

1. In order to protect the fluid cylinder from washing before sustained pumping begins, the tapered
valve seats must be pressured up and fully seated creating a positive fluid seal.
2. Adjust the test choke for high pressure/low pump RPM. Shift the transmission to 1st gear and
slowly increase the throttle setting to achieve the value in the table below for 2 to 3 minutes or
until a series of audible popping noises are heard; indicating that the seats have seated in the
taper. The desired pressure for each plunger size is as follows:

Plunger Dia. Rated Pressure

3½” 9,200 PSI
3¾” 9,200 PSI
4” 9,200 PSI
4½” 5,900 PSI
5” 5,900 PSI
5½” 4,000 PSI
5¾” 4,000 PSI
6” 4,000 PSI
6½” 3,000 PSI

During this portion of the startup procedure, closely observe the plunger pump for any unusual
noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as elapsed time,
ambient temperature, power end lube oil temperature, power end lube oil pressure, supercharge
pressure, etc. After returning the engine to idle and transmission to neutral, physically inspect
the plunger pump before proceeding further.

D. Break-In Procedure:
1. Adjust the test choke, engine, and transmission to obtain approximately 32% rated rod load,
42% rated pump RPM, and 32% rated horsepower. These settings should be approximately as
follows:

Plunger Dia. Pump Crank Pinion RPM GPM/BPM PSI BHP

RPM
3½” 130 828 217/5.2 6,400 810
3¾” 130 828 249/5.9 5,600 810
4” 130 828 283/6.7 4,900 810
4½” 130 828 358/8.5 3,900 810
5” 130 828 442/10.5 3,100 810
5½” 130 828 535/12.7 2,600 810
5¾” 130 828 585/13.9 2,400 810
6” 130 828 637/15.1 2,200 810
6½” 130 828 748/17.8 1,900 810

Run the plunger pump at this setting for one hour. During this time, closely observe the plunger
pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end lube oil
pressure, supercharge pressure, etc. After returning the engine to idle and the transmission to
neutral, physically inspect the plunger pump before proceeding further.

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2. Adjust the test choke, engine, and transmission to obtain approximately 52% rated rod load, 52%
rated pump RPM, and 65% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM Pinion RPM GPM/BPM PSI BHP

3½” 160 1,019 267/6.3 10,400 1,620
3¾” 160 1,019 306/7.3 9,100 1,620
4” 160 1,019 348/8.3 8,000 1,620
4½” 160 1,019 441/10.5 6,300 1,620
5” 160 1,019 545/12.9 5,100 1,620
5½” 160 1,019 659/15.7 4,200 1,620
5¾” 160 1,019 720/17.1 3,900 1,620
6” 160 1,019 785/18.6 3,500 1,620
6½” 160 1,019 921/21.9 3,000 1,620

Run the plunger pump at this setting for one hour. During this time, closely observe the plunger
pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end lube oil
pressure, supercharge pressure, etc. After returning the engine to idle and the transmission to
neutral, physically inspect the plunger pump before proceeding further.

3. Adjust the test choke, engine, and transmission to obtain approximately 26% rated rod load, 100%
rated pump RPM, and 62% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM Pinion RPM GPM/BPM PSI BHP

3½” 307 1,949 511/12.1 5,200 1,550
3¾” 307 1,949 586/13.9 4,500 1,550
4” 307 1,949 667/15.8 4,000 1,550
4½” 307 1,949 844/20.1 3,100 1,550
5” 307 1,949 1,043/24.8 2,500 1,550
5½” 307 1,949 1,262/30 2,100 1,550
5¾” 307 1,949 1,379/32.8 1,900 1,550
6” 307 1,949 1,502/35.7 1,800 1,550
6½” 307 1,949 1,762/41.9 1,500 1,550

Run the pump at this setting for 30 minutes. During this time, closely observe the plunger pump for
any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as
elapsed time, ambient temperature, power end lube oil temperature, power end lube oil pressure,
supercharge pressure, etc. After returning the engine to idle and the transmission to neutral,
physically inspect the plunger pump before proceeding further.

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4. Adjust the test choke, engine, and transmission to obtain approximately 100% rated rod load, 35%
rated pump RPM, and 52% rated horsepower. These settings should be approximately as follows:

Plunger Dia. Pump RPM Pinion RPM GPM/BPM PSI BHP

3½” 66 417 109/2.6 20,000 1,275
3¾” 66 417 125/2.9 17,400 1,275
4” 66 417 142/3.3 15,300 1,275
4½” 66 417 180/4.3 12,100 1,275
5” 66 417 223/5.3 9,800 1,275
5½” 66 417 269/6.4 8,100 1,275
5¾” 66 417 295/7.0 7,400 1,275
6” 66 417 321/7.6 6,800 1,275
6½” 66 417 377/8.9 5,800 1,275

Run the pump at this setting for 30 minutes. During this time, closely observe the plunger pump for
any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such as
elapsed time, ambient temperature, power end lube oil temperature, power end lube oil pressure,
supercharge pressure, etc. Return the engine to idle, the transmission to neutral, and stop/ shut
down the engine.

5. Visually inspect the power end for oil leaks around the pony rod seals, pinion seal, lubrication hoses,
lube drain hoses, covers, etc.

Visually inspect the fluid end for fluid leaks around the suction covers, discharge covers, discharge
flanges, stuffing boxes, and suction manifold. Visually inspect the plungers for any signs of heating
or scoring.

Remove the power end lube system magnet and inspect for any unusually large particles of metal.
Change the lube oil filters.

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 Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

SECTION III: Maintenance and Repair

Routine Preventative Maintenance:
Maximum service and trouble-free operation can be obtained from the SPM® well service plunger pump by
establishing a thorough preventive maintenance program as follows:

During The First 100 Hours of New Pump Operation:

 Change power end lube oil filters every 25 hours (or more often if required) to prevent filter bypass.
 Thoroughly clean the power end lube oil suction strainer after the first 50 hours and then every 100
hours operation.
 Change the power end lube oil after the first 100 hours operation and clean the lube oil reservoir.

Daily Preventive Maintenance:

 Check the oil level in the power end lube oil reservoir.
 Check the oil level in the plunger lube oil reservoir.
 Check the plunger pump for oil leaks and/or fluid leaks.
 Check the power end lube oil system for leaks.
 Check the plunger lube system for leaks.
 Check the supercharge piping for leaks.
 Visually check for loose bolts in the following locations:
 Power End mounting bolts.
 Stay Rods.
 Discharge Flanges.
 Companion Flange.
 Packing Nuts.
 Retainer and Discharge Nuts.
 If the suction stabilizer has a nitrogen filled bladder, check the nitrogen charge pressure and
correct as needed. Follow the manufacturer’s charging pressure recommendations, usually 60%-
80% of suction inlet pressure.

Weekly Preventive Maintenance:

 Check all items on “daily” list.
 Check all valves, inserts, valve seats, and springs.
 Check all discharge and suction cover seals.
 Check suction pulsation dampener for correct pre-charge.

Monthly (or every 100 hours) Preventive Maintenance:

 Check all items on “daily” and “weekly” lists.
 Check all fluid cylinder mounting bolts to insure that they are tight with a torque wrench.
 Check all plunger pump-mounting bolts to insure that they are tight.
 Change power end lube oil filters.
 Check all supplies needed for routine maintenance such as o-rings, fluid seals, valves, valve inserts, valve
seats, valve springs, packing, oil seals, filter elements, etc.

Quarterly (or every 250 hours) Preventive Maintenance:

 Check all items on “daily”, “weekly”, and “monthly” list.
 Change the power end lube oil and refill with the proper grade of gear oil for upcoming ambient
conditions.
 Thoroughly clean the power end lube oil suction strainer.

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Revision: E

Quarterly (or every 250 hours) Preventive Maintenance (Cont.):

 Remove and inspect the plungers and packing assembly components. Replace all packing pressure
rings and header rings.
 Clean the plunger pump’s oil breather and the power end lube oil reservoir breather.
Yearly (or as required) Preventive Maintenance:

 Replace worn plungers and packing brass.

 Replace worn or corroded valve covers, suction valve stops, packing nuts, discharge flanges, pump
tools, etc.
 Replace all discharge flange seals and suction manifold seals.
 Replace any defective gauges and instruments.
 Inspect (and rebuild if necessary) the power end lube oil pump.

It is difficult to assess wear and tear on a pump based solely on hours operated, due to the variations in duty
cycle and types of service. However, roller bearings, rod bearings and gearing may need replacing after
approximately 1200 to 3000 hours. With either component, signs of extensive wear will generally show up as
spalling, or flaking off, of material causing pitting or scoring on the working surfaces. A small amount of this is
tolerable on gear faces, but any spalling on a bearing surface is an indication to replace that item as quickly as
feasible.

While replacement of these major components is relatively expensive, failure of a main bearing can quite often
lead to power frame, crankshaft, or other serious damage.

Close observation of the lube oil filters during routine maintenance will generally indicate the condition of roller
bearings, gears, and journal bearings. A routine of pulling the inspection covers and observing the condition of
the bearings and gears every 500 hours is recommended.

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Revision: E

Troubleshooting Guide:
TROUBLE SYMPTOM: PROBABLE CAUSE:
A.) Abnormally high vacuum at power 1. Extremely cold ambient temperature/dangerously high
end lube pump suction inlet (may oil viscosity.
or may not be accompanied by 2. Clogged lube system suction strainer.
abnormally low oil pressure). 3. Kinked or collapsed lube system suction hose.
4. Clogged oil reservoir breather.
5. Erroneous gauge reading.

B.) Abnormally low power end lube 1. Leak in lube pump suction piping, which allows air to be
oil pressure with normal to low drawn into the system.
vacuum reading at lube pump 2. Worn or damaged lube pump.
suction (may or may not be 3. Leak in lube pump pressure piping.
accompanied by high oil 4. Low oil level in reservoir.
temperature). 5. Clogged oil filter element.
6. Faulty lube system relief valve.
7. Extremely hot lube oil temperature/dangerously low oil
viscosity.
8. Erroneous gauge reading.

C.) Abnormally high power end lube 1. Extremely warm ambient temperature/dangerously low
oil temperature (may or may not oil viscosity/incorrect grade of gear oil.
be accompanied by low oil 2. Gear oil contaminated with water, trash, or air bubbles.
pressure). 3. Plunger pump has been operated continuously for too
long a period of time at or near its maximum
horsepower or torque rating.
4. Heat exchanger or oil cooler malfunction.
5. Erroneous gauge reading.
6. Internal power end damage or power end wear.

D.) Leaking power end oil seals. 1. Extremely cold ambient temperature/high oil viscosity.
2. Damaged seal surface on mating part.
3. Clogged oil breather/high crankcase pressure.
4. Worn or damaged seal.
5. Contaminated lube oil.
6. Loose inspection cover bolts or torn inspection cover
gaskets or sealing bonded inspection cover bolt washers.

E.) Leaking lube lines. 1. Loose fittings or damaged hoses.

F.) Leaking fluid end seals. 1. Seal installed improperly.

2. Seal cut or pinched on installation.
3. Mating seal surface not cleaned properly prior to seal
installation.
4. Damaged or corroded mating seal surface.
5. Sealing part not properly tightened.

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 Document P/N: 2P121267
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Revision: E

TROUBLE SYMPTOM: PROBABLE CAUSE:

G.) Plunger and/or packing fluid leak. 1. Packing nut not tightened properly.
2. Worn or damaged packing.
3. Packing installed improperly.
4. Mating seal surface not cleaned properly prior to packing
installation.
5. Damaged or corroded mating seal surface.
6. Fluid being pumped is incompatible with the style packing
being used.
7. Wiper ring damaged or installed improperly.

H.) Fluid knock or hammer. 1. Air entering supercharge system through loose, worn or
damaged connections.
2. Air entering supercharge system through leaking charge
pump seals.
3. Fluid being pumped contains gas or vapor.
4. Insufficient supercharge flow or pressure.
5 Valve cocked open/broken valve spring or valve stop.
6. Worn or damaged valve, valve insert, or valve seat.
7. Improperly charged or ineffective suction pulsation
dampener.

I.) Low discharge pressure/rough 1. Worn or damaged valve, assembly.

running pump. 2. Insufficient supercharge flow or pressure.
3. Air, gas, or vapor in fluid being pumped.
4. Improperly charged or ineffective suction pulsation
dampener.
5. Two or more plunger pumps being supercharged by a
common charge pump and getting “in phase” with each
other.

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 Document P/N: 2P121267
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Revision: E

SPM® QWS2500 SD Duralast™ Fluid End Removal:

1. Disconnect suction and discharge manifolds lines, plunger lube lines and plunger lube check
valves, and pressure transducer electrical lines.

a) Remove Plunger Clamps using a pneumatic/ratchet wrench and a 3/8" Hex Bit.

2. Ensure that the two SPM® provided lifting eyes are installed and torqued per engineering drawing,
attach lifting chain and overhead hoist (5 Ton minimum capacity) to prevent Fluid End from
falling off the Power End. See Lifting Requirements section. Remove the slack from the lifting
chains.

3. Using a 23/4 wrench, remove the twenty 13/4 nuts which secure the fluid cylinder to the power end
stay rods. Remove the fluid cylinder from the power end.

4. Set the fluid end on a pallet up right

5. Inspect the face of the fluid cylinder for wear of fretting around the stay rod holes. Inspect the
shoulders of the stay rods for wear or cracks. Check all twenty stay rods for the correct torque
(1000 ft. lbs. with lubricated threads) prior to reinstalling the fluid cylinder. For two piece stay
rods, the inner rod should be bottomed out into the power end with no additional applied torque.

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Revision: E

SPM® QWS2500 SD Grooved and Grooveless Fluid End Removal:

1. Remove the plunger clamps and separate each plunger from each pony rod as outlined earlier in
“To Change Plungers and Packing”.
2. Disconnect the plunger lube hoses and whatever discharge piping connections and suction piping
connections are necessary for fluid end removal.
3. Using a 2¾” wrench, remove the twenty 1¾” nuts which secure the fluid cylinder to the power
end stay rods. Remove the fluid cylinder from the power end and set fluid end on pallet upright.

4. Inspect the face of the fluid cylinder for wear or fretting around the stay rod holes. Inspect the
shoulders of the stay rods for wear or cracks. Check all twenty stay rod nuts for the correct torque
(1000 ft. lbs. with lubricated threads) prior to reinstalling the fluid cylinder.

NOTE: IF A HYDRAULIC POWERED TORQUE WRENCH IS NOT AVAILABLE, HAND TIGHTEN EACH STAY
ROD AS TIGHT AS POSSIBLE WITH A 2” END WRENCH, THEN TURN THE STAY ROD ANOTHER 30
DEGREES CLOCKWISE WITH AN OPEN END HAMMER WRENCH.

5. Reinstall the fluid cylinder. Clean and lubricate the stay rod threads, then hand tighten the 1¾”
nuts as tight as possible with a 2¾” wrench. If a hydraulic powered torque wrench is not available
to tighten the nuts to 2000 ft. lbs., turn each nut another 30 degrees past hand tight with a 2¾”
hammer wrench.
6. Reinstall the plunger lube hoses, discharge piping connections, and suction piping connections.
7. Reinstall the plunger clamps as outlined earlier in “To Change Plungers and Packing”.

NOTE: IF INSTALLING A DIFFERENT SIZE FLUID CYLINDER, A DIFFERENT PLUNGER CLAMP MAY BE
REQUIRED.

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 Document P/N: 2P121267
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Revision: E

SPM® QWS2500 SD Power End Repair Procedures:

Due to the complexity of the task and the need for special tools and training, Weir Oil and Gas does not
recommend the complete disassembly and major repair of the QWS2500 SD power end in the field. If
extensive power end repairs are required, the pump should be returned to the Weir Oil & Gas plant where
expert service can be obtained on an expedited emergency basis if needed. When field repairs are necessary,
they should be performed in a clean well equipped shop by a trained well service pump technician, and should
follow the guidelines below. Disassembly or tampering beyond the procedures detailed below could result in
the voiding of warranty.

To Replace a Pony Rod or Pony Rod Seal:

1. Using a 3/8” hex key wrench, remove the two 1/2” socket head capscrews from the plunger
clamp. Separate the two halves of the plunger clamp and remove them from the pony rod. If
more than one clamp is removed, take care to keep the clamp halves in matched pairs. Inspect
each clamp for wear or damage to the inside surface.
2. Remove packing nut lock if applicable. Using the SPM® packing nut tool, loosen the packing nut
one full turn. Separate the plunger from the pony rod taking care to avoid damaging the mating
face of either. Slide the plunger all the way into the fluid end.
3. Using a 9/16” wrench, remove the eight 3/8” capscrews which secure the pony rod seal retainer
to the power end. Remove the pony rod seal retainer and it’s gasket from the power end. Using a
7/16” wrench, remove the three 1/4” capscrews and 1/4” washers which retain the pony rod seal.
Inspect the double lip pony rod oil seal for damaged, worn, or hardened non-pliable sealing lips
and replace the seal if necessary.
4. Cut the tie wire which is laced through the six 3/4” socket head capscrews that secure the pony
rod to the crosshead. Using a 5/8” hex key wrench, remove the six 3/4” socket head capscrews.
Remove the pony rod from the power end and inspect it for wear and damage to the seal surface
and clamp end.
5. Reassembly should be performed in the reverse order of the procedure above.
Care must be taken to avoid damaging the sealing lips of the pony rod oil seal upon reinstalling
the seal retainer. A new gasket should also be installed to prevent oil leaks.

Refer to the drawing packing in this manual for tightening all capscrews, etc. to proper torque
values.

To Replace a Stay Rod:

1. Remove the fluid end as outlined previously in the “Fluid End Repair Procedures” section of this
manual.
2. Using a hydraulic torque wrench, remove the stay rod from the power end. Two piece stay rods
should not require a hydraulic torque wrench for removal.Inspect the stay rod for wear on the face
of the shoulders at each end and for cracks in the thread roots and near the shoulders at each end.
3. Inspect the mating face of the power end housing for wear and fretting. Check the threads in the
power end face for wear and damage.
4. Reinstall the affected stay rods (and fluid end as outlined previously). Torque the stay rod as
shown below. Again for two piece stay rods, the inner rod should be bottomed out into the power
end noseplate with no additional applied torque.

a.) Stay rod torque at nose plate…….……1000 ft-lb.

b.) Nut torque at cylinder flange…………2000 ft-lb.
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 Document P/N: 2P121267
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Revision: E

SECTION IV: Pump Parts

General Information:
Weir Oil & Gas stocks a large inventory of genuine original equipment replacement parts for each of its pumps.
In order to expedite a parts order and avoid any delays, please provide the following information with your
order:
1. The part number and description (refer to drawings and parts lists in this section) of each item ordered.
2. The quantity of each part, kit, or assembly ordered.
3. The model number and serial number of the pump (see identification tags on the fluid end and power
end).
4. Your purchase order number.
5. Specify method of shipment, complete shipping address, complete billing address and telephone
number at the destination of the shipment.

Parts and service may be ordered through the locations listed on the following page, as well as the Weir Oil &
Gas web page at www.weiroilandgas.com:

There is a 25 percent restocking charge for any returned, undamaged parts. Returned parts must include a
Weir Oil & Gas issued “Return Authorization Number” on the shipping label and packing list. Parts must be
returned within 90 days of the original shipping date. Returned parts must be shipped prepaid, to the
appropriate address, including a copy of the original invoice or delivery ticket.

Weir Oil & Gas

601 Weir Way Tel: (817) 246 2461

Fort Worth Fax (817) 246 6324
TX 76108
USA www.weiroilandgas.com

Copyright © 2014, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information
in this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any
purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON,
SAFETY HAMMER, SUR-DROP, DESTINY, STAMPEDE, VERIBAND, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow
Control, Inc.. WEIR is a trademark and/or registered trademark of Weir Engineering Services Limited. Certain features of some of the products disclosed in
this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..

49
 www.weiroilandgas.com
www.weirinaction.com
Headquarters:
601 Weir Way | Fort Worth, TX 76108 | Ph: +1-800-342-7458 | Fax: +1-817-977-2508

NORTH AMERICA:
Fort Lupton, CO–Service Center Villahermosa, Mexico–Service Center
Deer Park, TX–Service Center
13055 Weld County Road 8 Bodega 3, Lote 8, Manzana 3
920 Seaco Court
Fort Lupton, CO 80621 Sobre Calle San Lazaro
Deer Park, TX 77536
Ph: +1-303-535-5450 Parque Logistico Industrial, Tobasco
Ph: +1-832-200-6220
Fax: +1-303-535-5455 Villahermosa, Tabasco 86150
Fax: +1-832-200-6227
Ph: +52-993-142-7083
Mid Continent:
Grand Junction, CO–Service Center EUROPE, MIDDLE EAST, AND AFRICA:
Bossier City, LA–Service Center 842 21 ½ Rd., Building A
Aberdeen, Scotland–Service Center
2403 Grimmett Dr. Grand Junction, CO 81505
Badentoy Industrial Park, Portlethen
Shreveport, LA 71107 Ph: +1-970-243-4600
Aberdeen AB12 4YD, Scotland
Ph: +1-318-677-2422 Fax: +1-970-243-8027
Ph: +44-1224-783666
Fax: +1-318-677-5385
Williston, ND–Service Center Fax: +44-1224-784184
Elk City, OK–Service Center 5073 Owans Industrial Park Drive
Dubai, UAE–Service Center
2111 S. Main Williston, ND 58801
Oilfields Supply Center, L.T.D., Building 18
Elk City, OK 73648 Ph: +1-701-572-0776
P.O. Box 1518, Jebel Ali, Dubai, UAE
Ph: +1 580-225-2385 Fax: +1-701-572-0784
Ph: +971-48836-368
Fax: +1 580-225-3402
South and West Texas: Fax: +971-48836-485
Fort Worth, TX–Service Center
Odessa, TX–Service Center ASIA PACIFIC:
7711 Wyatt Drive
2424 E. I-20
Fort Worth, TX 76108 Indonesia–Service Center
Odessa, TX 79766
Ph: +1 817-935-7964 Jl. Mulawarman No.20 RT 20
Ph: +1-432-580-3887
Fax: +1 817-935-7365 Manggar, Balikpapan, Kalimantan Timur
Fax: +1-432-333-1351
Indonesia 76116
Kilgore, TX–Service Center
Pleasanton, TX–Service Center Ph: +62 542 74 6098
1102 State Hwy 31 W
772 HWY 281 South
Kilgore, TX 75662 Singapore–Service Center
Pleasanton, TX 78064
Ph: +1-903-984-8153 15 Tukang Innovation Drive,
Ph: +1-830-569-351
Fax: +1-903-984-8626 Singapore, 618299
Fax: +1-830-569-3643
Ph: +65-6302-0852
Lafayette, LA–Service Center
Canada: Fax: +65-6302-0883
401 S. Bernard Rd.
Broussard, LA 70518 Edmonton, AB, Canada–Service Center Perth, Australia–Service Center
Ph: +1-337-837-3161 4743 97th St. Henderson Service Center
Fax: +1-337-839-1985 Edmonton, AB T6E 5W2 20 Stuart Drive
Ph: +1-780-438-1122 Perth, Western Australia 6166
Searcy, AR–Service Center
Fax: +1-780-437-5218 Ph: +61-8-9410-7500
2211 Taylor Road
Searcy, AR 72143 Grande Prairie, AB, Canada–Service Center Adelaide (AUS)–Service Center
Ph: +1-501-305-3296 8801 99th Street 174 Cormack Road
Fax: +1-501-305-3419 Clairmont, Alberta T0H 0W0 Wingfield
Ph: +1-780-567-3857 Adelaide, SA, 5013
Northeast:
Fax: +1-780-567-2808 Ph: +61-8-8285-3133
Buckhannon, WV–Service Center Fax: +61-7-8285-3151
Medicine Hat, AB, Canada–Service Center
52 Norwins Drive
1202 Dirkson Drive N.E. Chengdu, China- Service Center
Buckhannon, WV 26201
Redcliff, Alberta T0J 2P0 333 No. Xin Gong Road
Ph: +1-304-472-9701
Ph: +1-403-504-8353 Xin Du, Cheng Du
Fax: +1-304- 472-9130
Fax: +1-403-504-8370 Si Chuan, China 610500
Williamsport, PA–Service Center Ph: +86-28-83924721
Red Deer, AB, Canada–Service Center
76 Odell Road Fax: +86-28-83924722
Unit A, 8060 Edgar Industrial Crescent
Muncy, PA 17756
Red Deer, Alberta T4P 3R3 MANUFACTURING:
Ph: +1-570-546-1005
Ph: +1-403-341-3410
Fax: +1-570-546-2033 Novatech
Fax: +1-403-341-3072
8388 C.F. Hawn Freeway
LATIN AMERICA: Dallas, TX 75217
Rockies:
Ph: +1-214-398-1491
Macae, Brazil–Service Center
Denver, CO–Sales Office
Rua Internacional, No 245,
950 S. Cherry Street, Suite 312
Granja dos Cavaleiros
Denver, CO 80246
Macae, RJ Brazil
Ph: +1-303-535-5450
Ph: +55-22-2106-8750
Fax: +1-303-535-5455
Fax: +55-22-2106-8777

Updated: 1/12/16
 Document P/N: 2P121267
Release Date: 01/15/2015
Revision: E

Power End Drawings:

51