A08012200E D en TPH400

Service Manual
400 Pump
1
Section 1
400 Pump Description
2
SJS 400 PUMP
The 400 pump is used in all phases of oilfield operation to pump water,
cement, fracturing fluids, and other stimulation fluids. The three main parts of
pump are (1)the power end, (2)the spacer, and (3)the fluid end.
Power End
The power-end assembly reduces speed, multiplies torque, and changes
rotary action into reciprocating action. It takes energy delivered by the engine
and transmission and changes it into energy that can be used by the fluid end.
Power ends are customized to meet job requirements and conserve space on
the trailer or truck unit. Cases are available in right- and left-hand versions. We
use Holroyd gear sets (8.6:1) for 400 pump.
Other customizing features include the following:
lube systems
companion flanges
worm- and ring-gear ratios
heat exchanger design
Spacer
On most pump configurations, a steel spacer assembly is used between
the fluid end and the power end. The spacer helps prevent fluids from
escaping from the fluid end into the power-end cavity (sump).
All new pumps require spacers. Fracturing pumps require L-2 spacers and
3
cement pumps require L-4 spacers.
Some spacers require push-rod noses uniquely designed to match the
fluid-end size used, while other spacers may use more than one type of wiper
gland.
Fluid End
The fluid end uses energy that has been modified by the power end to move
cement, fracturing mediums, and other liquids and materials.
The 400 pump fluid end, which is available in two sizes, can be customized for
many applications. The fluid end accepts a variety of discharge flanges and
plunger lubricators. Different lengths of plungers and tie bolts are used. A
variety of valve and seat combinations are available, and different springs and
inserts can be installed on these valves.
Design Features
The following features are unique to the 400 pump:
It can pump at pressures as high as 20,000 psi (137.6 MPa).
It is lightweight and compact, and can be airlifted into remote areas.
It provides high performance and long life.
It has three separate fluid-end sections that can be replaced individually.
4
Specifications and Data
The following pages contain lists and schematics of the 400. Tables 1.2
through 1.7 provide information regarding power-end and fluid-end
components, pump assembly weights, and discharge pressures. Table 1.7
(Page 1-26) provides pump dimensions.
Figure 1.10 provides general dimension data for the 400 pump.
Table 1.2Power End

Companion Flange 1800 Series Spicer
Input Spline 3-in.10 (7.62 cm)
Input Rotation Clockwise
Plunger Stroke 8in(203.2mm)
Input Speed w18.4:1 or 8.6:1 2,400 (Maximum rev/mm)
Gears
Maximum Input Torque 7,215 lbf (9,782.227 N.m)
Maximum Input Horsepower 600hp(447kw)----8.6:1
Gear Train Steel worm and bronze ring w/ 8.6:1 ratio
(standard)
Crankshaft Forged steel, four main bearings
Connecting Rods Three, forged aluminum, split caps, and
insert bearings
Crossheads Three, cast steel
Case High-strength steel weldment
Bearing Type Roller and race
Oil System Gear pump driven off worm (std) or remote
Oil Filter Replaceable elements and magnetic
strainer (Schroeder)
Oil Capacity 22 U.S. gal (0.083m3)
Oil Pressure 80 to 100 psi (0.552 to 0.689 MPa)
Minimum Oil Flow Schroeder 35 to 40 psi (0.241 to 0.276
MPa) at
190 worm-gear rev/mm
Weight (wet) 3,864 lb (1,752.681 kg)
Table 1.3Pump Assembly Weight

Spacer lb (kg)
Size in. (mm) L-4 Spacer
3 3/8(85.73) 5.731(2599)
4 (101.6) 5,556(2520)
4 1/2(114.3) 5,597 (2538)
5
Table 1.4Fluid End
Fluid-End Type Horizontal, triplex, three-piece forged steel
Plunger Type Single-acting, hard-surfaced
Valve Type Double-guided, carburized, high-contact
Valve Seats Carburized and replaceable
Pressure Packing CDI High performance packing
Discharge Flange (1) Blank, straight with one outlet or (2) ell with two
outlets
Oil System External; use air tank press
Table 1.5Fluid-End Weight

Size in. (mm) Weight lb (kg)
3 3/8(85.73) 1.725(782.447)
4 (101.6) 1,550 (703.068)
4 1/2(114.3) 1,591 (721.666)
Table 1 .6Discharge Pressure

Maximum Working
Size in. (mm)
Pressure psi (MPa)
3 3/8(85.73) 20.000(137.895)
4 (101.6) 15,000 (103.4)*
4 1/2(114.3) 11,200 (77.221)
*For static pressure testing, such as testing lines, BOP
stacks, etc., the 4-in. (10.160-cm) fluid end is rated
to15,000 psi (103.421 MPa) maximum pressure.
6
7
400 Duty Ratings
The following operation limits are based on experience working with the
400 pump in Halliburton pumping operations.
Warning: Do not exceed the operation limits listed for each gear.
Exceeding the operation limits can result in severe or
fatal injury as well as equipment damage.
Operation Limits (8.6:1 gear)

Intermittent: Fewer than 4 hours
600 bhp (577 hhp), 100% maximum pressure, 275 crank rev/m
Intermediate: Between 4 and 8 hours
390 bhp (375 hhp), 75% maximum pressure, 250 crank rev/m
Continuous: More than 8 hours
275 bhp (264 hhp), 50% maximum pressure (Optimum pump
life is attained at 25% maximum pressure), 75 crank rev/m
8
RubberParts(Packing,Seals,etc.)ChemicalResistance
ServiceType FluidsPumped
Water
Cementslurries
Completions/Cementing
Drillingmud(water&oilbased)
Brines(NaCl,KCl,etc.)
Waterbasedfracfluids
Stimulation/Fracturing Acids(dilutehydrochloric,hydrofluoric,acetic
w/corrosioninhibitors)
Gelled(polymer)waterbasedfluids
Acids(dilutehydrochloric,hydrofluoric,acetic
CoiledTubing
w/corrosioninhibitors)
Drillingmud(water&oilbased)

RubberParts(Packing,Seals,etc.)ChemicalResistanceTables
Chemicals Resistance Chemicals Resistance
AcetateSolv.,Pure X HydrocyanicAcid B
AceticAcid5% B LacticAcid B
AceticAcid10% B Toluene X
AceticAcid20% B Xylene X
AceticAcid30% B SulfuricAcid 10% C
AceticAcid50% A SulfuricAcid 30% C
AceticAcidGlacial X SulfuricAcid 50% C
HydrochloricAcid10% B SulfurousAcid X
HydrochloricAcid20% B DieselFuel A
HydrochloricAcid28% B CyanicAcid A
HydrochloricAcid37% C Petrolatum A
Alcohol A potash C
Aldehyde X SeaWater A
Benzene C Sewage A
Brine A SodiumNitrate C
CrudeOil X SodiumChloride A
PotassiumChloride A SulfurousAcid X
NOTES: A=Excellent,noeffect; B=Good,minoreffect;
C=Fair,datanotconclusive,testingrecommend;
X=Notrecommended.
Ratingsarebasedontestingatanambienttemperatureof70F.Customer
shouldtesttodetermineapplicationsuitability,Ifyouhaveanyquestionsplease
contactSJSEngineerDepartment.
9
SHIPPING AND STORAGE
All pumps are shipped dry and must be flushed and filled with the proper
Lubricant before operating. 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 saltwater
contamination.
New pumps are not prepared for long periods of storage and should be
put in service as soon as possible. To prepare a pump for storage after prior
use,clean the fluid end and flush it with a good rust preventive, Plug all fluid
end discharge and suction openings. Drain oil from power end, thoroughly
clean and flush with a good rust preventive that will not clog oil passages.
Remove crankcase breather and plug all openings. Coat the pinion extensions
and pony rods with a heavy rust preventive. Store pump inside, in a warm, dry
place.
*After store a period of time(three months or more), please be sure
theseals are OK. Normally the quality guarantee period of the seal is 1
year when the seal are stored indoor and the temperature is 20. Please
be sure the condition of the storage and compare it with the recommend
storage condition about the quality guarantee period. If necessary, the
seals should be replaced before working.
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 plunger packing and valve
inserts will stick to the matching metal parts and become damaged upon
start-up if not disassembled and lubricated first.
10
Section 2
General Maintenance
11
Safety
Read all of the warings and safety guidelines in this manual before you put a
TPH400 pump in service. Failure to read and follow all of the safety warings in
this manual can result in serious injury, death, and equipment damage.
Warning
Follow all precautions below in consideration of safety in maintenance and
require.
Safety Precautions
Before you work on a TPH400 pump, check the following items:
1. Wear personal protective equipment (PPE). Review the PPE manual for
specifications on hard hat, goggles, gloves, steel-toed shoes, etc.
2. Flush the pump to remove any acids or other harmful chemicals that could
cause bodily harm if contacted.
3. Carefully bleed pressure from the fluid end. Isolate the pump from pressure
and vent the pump to atmosphere before beginning work.
4. Turn off the prime mover (engine or electric motor).
Warning: Never place your hand into the fluid end or spacer area of a
pump when the prime mover is on. Serious or fatal injury could result.
5. Disengage the prime mover from the pump (transmission in neutral) or lock
the electric motor to prevent accidental startup.
6. File down or replace parts that have sharp or jagged edges.
7. Use a remote-operated choke to build pressure in a positive-displacement

pump
Warning: Never use a full-closing valve to build pressure in a positive

displacement pump. A sudden overpressure could occur, causing
serious injury or equipment damage.
8. Use care when lifting or moving pump parts. Many of these parts are heavy
enough to cause injury if improperly handled. Lift parts with other personnel or
use a hoist or other lifting device.
12
9. If the pump input shaft is turned by a tool (such as a pry bar or pipe wrench),
remove the tool immediately after use.
Caution: Do not start the pump when the tool is still attached to the
driveshaft, serious damage or injury could occur.
10. Before starting the pump, make sure all discharge valves are open and all
protective guards are installed.
11. Never weld on a pressure-containing part (such as a fluid end, discharge

flange, etc.) without prior approval of SJS.
Warning: Failure to follow all precautions could result in serious or fatal

injury.
Warning: Do not operate a TPH400 pump if the pump has fatigue cracks.
Operating an pump with fatigue cracks can result in severe injury, death,
and equipment damage.
The fluid end is working at a cyclic load with each plunger stroke. Therefore,
many of the fluid-end components are susceptible to fatigue cracking,
especially the high-pressure cementing services.
The following parts should be checked:
Cylinder
Cylinder-head covers
Cylinder-head retainers
Discharge covers
Discharge-cover retainers
Top tie bolts
Packing nuts
Discharge flanges
Warning: Do not operate H2S by TPH400 pump. Please contact with

Engineer Department of SJS for suited packing will be needed when
using non-standardized component.
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General Maintenance
Introduction
Prejob Maintenance
1. Check the oil quantity and quality in the power end. Add oil if the dipstick
shows that the level is low. Do not mix different types of oil.
Check the oil type. Making sure that the pour point is at least -12.2 below
working environment to guarantee fluidity. And consider characters of different
oil types. See more details in the Power-End Lubricants table additional.
2. You could check the jam situation of oil filter in its pointer field. Yellow means
cleaning will be needed. Take apart oil filter from lubricate pipe, then loosen
spring in the pointer and discharge pointer box lightly when you are cleaning.
Attention: do not damage O ring seal and pointer! Loosen top four bolts; take
down the body of oil filter straightly (oil usually reserves in it)Take out filter
gauze; clean with detergent and blow-dry. Invert this process could assemble
oil filter.
3. Check pump packing lubricant system, oilcan level, loosen pump packing
linker, check if whether oil spout and adjust air pressure in order to obtain
proper pump packing lubricant flow rate.
4. Check oil temperature in major pump power end and fluid end. Turn on heat
exchanger, making sure oil temperature > 6.Overcooling temperature will
make oil difficult to fluid and hard to form oil slick could damage equipment.
Maintenance During theJob

1. As the pump is put into operation, watch the gauges. At idle (190 worm
rev/min), oil pressure should not below 20 psi. At operating speeds, the
minimum oil pressure should be 80 to 100 psi (0.552 to 0.689 MPa), the
minimum working speed should be worm 755 rev/min, the minimum working
flow should be 135 oil L/min.
2. Adjust and discharge flange pressure. The 4 400 pumps maximum flange
pressure should be 15000 PSI (103.4 MPa), the 4.5 400 pumps maximum
flange pressure should be 11194 PSI (77.2 MPa). Caution: exceeding the
maximum working pressure will overload the power end, which may cause
severe injury, death, and equipment damage.
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3. Every 10 minutes check the packing to see if it is leaking, moment check the
packing to see if it is smoking. If it is leaking, tighten the pressure packing by
wrench (P40-09-009). If it continues to leak, change it (see repair guide). If it is
smoking, the plunger lubricator maybe malfunctioning or the packing is
pressure-locked and a spray bar is needed.
Maintenance After the Job

1. Turn off the plunger lubricator by using the shutoff valve or the air valve.
2. If acid or cement has been pumped, flush the fluid end thoroughly with water
and blow-dry.
3. Check the oil quantity and quality in the power end, especially after pumping
acid. A high level or milky appearance indicates that the oil is contaminated.
Eliminate the source of the contamination and change the oil. Please take
notes of the changing so that we could refer next time.
4. Observe the drag pointers on the filter.
5. Fill in work notes.
Power-End Lubricants
Lube Selector by outside
Temp.()
Lubricant Pour point >10 -6.7~10 <-6.7
Mobilube HD 85W-140 -17.8 x x -
Mobil Extra Hecla Super Cylinder Oil 4.4 x - -
Mobilgear 636 -6.7 x - -
Mobil gear 634 -6.7 x - -
Mobil gear 632 -17.8 - x -
Philube SMP Gear Oil SAE85W/140 Stock No.90941 -17.8 x x -
Philube SMP Gear Oil SAE85W/140 Stock No.90931 -26.1 x x -
Philube SMP Gear Oil SAE80W/90 -28.9 - - x
Hector 3000 S-Stock No.80740 -12.2 x - -
Hector 3000 S-Stock No.80710 -9.4 x x -
Shell Spirax HD 85w/140 -20.6 x x -
Shell Spirax HD 80w-90 -26.1 - - x
Union Worm Gear Lube SAE 140 -12.2 x - -
Union MP Gear Lube SAE 85w/140 -12.2 x x -
Union MP Gear Lube SAE 80w/90 -28.9 - - x
Overload worm oil L-CKE/P Primes Viscosity 198 -12 x - -
242
Overload worm oil L-CKE/P Quality products -6 - x x
Viscosity 198242
Domestic high load vehicle gear pound 80w/90 Select oil prudently according to pour point
15
Notes
1. As lubricant working temperature >67, you should more frequently check

and replace it.
2. Make most of oil list above. Please contact with engineer division of SJS
when using non-listed oil.
3. Lubrication function will reduce if you mix artificially synthesized lubrication

into standard lubrication.
4. Recommend use extreme-pressure additive which has not contain sulfur

phosphoric, otherwise useful time of aldary worm would be reduce.
Packing lubricants
Packing lubricants had better adopt rock drill engine oil that adds in two
kinds of additives: thickening agent could make oil adhere to plunger and
packing better; ultimate additive could reduce wear under conditions where
rubbing or sliding accompanies high contact pressures. Actually power end
lubricant also could up to packing lubricant, but higher cost.
Caution: Do not use engine oil smooth packing. Although it is expensive, it
would reduce packings useful time.
Lube Selector by outside

Temp.()
Lubricant Pour point >10 -6.7~10 <-6.7
AMOCO Rock Drill Oil Light -26.1 - x x
AMOCO Rock Drill Oil Med -12.2 x x -
AMOCO Rock Drill Oil Hvy -6.7 x - -
ARCO Truslide 32 -28.9 - - x
ARCO Truslide 150 -26.1 x x -
ARCO Truslide 220 -15 x - -
CHEVRON Vistac-Grade 320X -8.9 x - -
CHEVRON Vistac-Grade 220X -15 x - -
CHEVRON Vistac-Grade 150X -15 x x -
CHEVRON Vistac-Grade 100X -17.8 - x x
CHEVRON Vistac-Grade 68X -23.9 - - x
16
GULF Rock Drill 32 -45.6 - - x
GULF Rock Drill 100 -31.7 x x -
GULF Rock Drill 320 -15 x - -
MOBIL Alamo Oil 525 -23.3 - - x
MOBIL Alamo Oil 527 -28.9 x x -
MOBIL Alamo Oil 529 -23.3 x - -
Notes:
1. If packing has premature damage, check if scratch exists in appearance
and packing hole exists in pump head scar. If these problems are not existed,
please consider whether crosshead sliding bush wear result in crosshead
clearance exceed and make plunger jump up.
2. In order to make packing operate normally, compress packing (2000PSL
first level) to reach max pressure (usually 2/3 max pressure) by pressurizing
progressively. Then tighten packing and maintain 20-30 min.
Tighten packing max pressure

Fluid-end plunger size Packing pressure
3 3/8 13333PSI(91.951MPa)
4 9300PSI(64.121MPa)
4.5 7500PSI(51.711MPa)
400 overload restriction

(Please do not work overtime, or else equipment useful time would reduce.
causing equipment damage even. Restrictions below come from oilfield
practical work summary.)
Operation restriction (8.6:1)
Discontinue: continue working less than 4 hours.

400 bhp(384hhp), 100% max pressure275 stroke speed
Interval: continue working between 4 hours and 8 hours

390 bhp(375hhp), 75% max pressure250 stroke speed
Continue: continue working more than 8 hours

275 bhp(264hhp), 50% max pressure 75stroke speed
17
Section 3
Structure and Repair
18
Maintenance and repair guide
Maintenance:
1. Check fluid-end valve component tools every 10 accumulative working
hours or 5 times.
2. Check worm tooth situation by tearing down worm box sideboard every
100 accumulative working hours or 3 months. If worm tooth appear
obvious chasm, major pump need to take apart and replace new worm. If
worm tooth become black, it indicates worm tooth appear centralized
pressure area which would aggravate worm wear. SJS strongly
recommend changing worm for its low safety may cause equipment
damage and serious injury.
3. Chang power-end lubricant and open power-endheat exchanger which
should clean by diesel oil every 200 accumulative working hours or 6
months.
Attention: If use artificial lubricant, such as Mobil SHC-634, the cleaning
time of the power-end could prolong until 1000 accumulative working
hours or 2 years.
4. Clean Purolator every 6 months or after changing power-end lubricant
even if Purolator do not indicate yellow.
Youd better make a periodic repair plan which could
prevent equipment from working abnormally cause by
temperature for spring and autumn separately
19
Power-End Repair
Minor repairs to the 400 power end can be made in most field camps and
on location, such as change packing, oil seal, valve etc. However, if the
pump requires an overhaul, send it to SJS.
Introduction
The power-end assembly reduces speed, multiplies torque, and changes
rotary action into reciprocating action. The assembly takes energy
delivered by the energy and transmission and changes it into energy that
can be used by the fluid end.
Power-end repair should adopt specialized tools (some unlisted

specialized tools accept customizing). Fluid-end parts that link with
crosshead such as plunger should take down firstly, then power-end
lubricant system ram component worm component crankshaft
component.
20
P40-09-000 TOOL ASSEMBLY
P40-09-001 0001 WRENCH,SOCKET,PLUNGER TIE BOLT NUT
P40-09-002 0002 TOOL,PLUNGER REMOVING 4-6 IN
P40-09-003 0003 TOOL,PACKING INSERTING
P40-09-007 0004 INSERT INSTALLING TOOL
P40-09-009 0005 WRENCH,PACKING NUT ADJUSTING
P40-09-030 0006 PULLER ASSY.,VALVE SEAT NO. 4 FRAC
P40-09-040 0007 TOOL, STOP AND SPRING INSTALLATION
P40-09-043 0008 SUPPORT, WRENCH 4 ADN 4 1/2"
P40-09-044 0009 PUNCH , GUIDE BUSHING REMOVING , NO.3 AND NO.4 VALVE
(Common tools list above and SJS accept customizing)
Tools also require:

Clean tools assorted.
Some parts require large ovens heating when reassembly.
High class instrument (include callipersmicrometeraltimeterbore dial

indicatorfeeler gauge etc).
Multi-size wrench and torque wrench.
Wire pump bracket.

21
Disassembly
Picture list blew is power-end of 400. It is a left end driver.
22
Pump preparation
1. Drain the oil from the power end.
2. Disconnected the plunger lubricant hose, the drive shaft, and the
coolant hoses. Remove the pump from the unit.
3. Move the plungers into the fluid end by turning the power-end input
shaft with a pipe wrench. Put the power end up on blocks and unfasten
the fluid-end mounts. Open suction board and unload plunger lug with
tool (P40-09-001), after that take down plungerplunger short pill-rod
plunger linking nuthandspikehandspike linking boltcrosshead linking
bolt.
4. Attach a chain and hoist to the fluid end. Take down 12 bolts in set with
wrench, and then take down fluid-end.
5. Remove the packing component if required.
Removing the Connecting Rods and Crossheads

1. Remove the three access covers.
2. Remove the three connecting-rod caps. Number the caps, making the
cap nearest the ring gear No.1.
3. Remove the crossheads and connecting rods. Consecutively number
the connecting rods, starting with the one nearest the ring gear.
Removing the Worm Gear

1. Remove the cover.
2. Remove the companion flange.
3. Loosen filter hoop, two pipes in power-end lubricant pipe, fixed bolt in
bypass valve, and take down bypass valve.
4. Loosen pipe hoop in lubricant pump, circumferential bolt in lubricant
pump, and take down lubricant pump.
5. Remove the three thrust races, two roller assemblies, the inner spacer,
and the outer spacer from the thrust-end retainer. Note the order in
which you remove them.
6. Remove the screw from the locknut, the locknut.
7. Remove the pump-drive adapter.
8. Remove the retainer cover, oil seal, and gasket.
9. Stir up worm with iron rod and knock out worm lightly from one side of
lubricant pump. Attention: Do not damage rolling bearing.
10. Take down worm feather key, rolling bearing outer ring.
23
24
Part # Item Description
P40-14-300 GEAR,WORM 8.6:1(HOLROYD)SUBASSEMBLY
|---P40-14-101 0001 SCREW,HEX SOCKER,3/8"-16NCx1 1/4",UNBRAKO/LOC-WEL
|---V06-68-473 0002 WASHER,FLAT,3/8" SAE,STEEL
|---P40-14-103 0003 COVER,OIL SEAL RETAINER
|---P40-14-104 0004 SEAL,OIL,53-IN. x 7448,FL,4"B x5 1/2"ODx1/2"WIDE
|---P40-14-105 0005 BEARING,DRIVE END-WORM SHAFT
|---P40-14-106 0006 GASKET,WORM HOUSING INPUT END
|---P40-14-107 0007 RETAINER,BEARING,WORM-DRIVE END
|---P40-14-308 0008 GEAR,WORM,SUB-ASSY,8.6:1 (HOLROYD),POWER-END ASSY
|---P40-14-109 0009 KEY,WORM-THRUST BEARING SPACER
|---P40-14-310 0010 ADAPTER-BROWN. SHARP LUBRICATOR PUMP
|---000P569267 0011 O-RING,NITRILE 90 DURO #267,PEROXIDE CURED
|---P40-14-115 0012 RETAINER,IRON WORM-THRUST END BEARING
|---P40-14-116 0013 BEARING,THRUST-END,WORM SHAFT
|---P40-14-117 0014 KEY,WORM-THRUST BEARING
|---P40-14-118 0015 BUSHING,WORM THRUST BEARING
|---P40-14-316 0016 STUD-LG LOC INSERT-TUTHILL OIL PUMP MTG
|---P40-14-120 0017 NUT,LOCK,SPLIT-WORM THRUST END,RIGHT HAND
|---P40-14-121 0018 SCREW,HEX SOCKET,NO.10,32NFx1/2",NYLOC INSERT
|---P40-14-122 0019 BEARING,THRUST,STACK WORM
|---P40-14-123 0020 SHIM,CLEARANCE,WORM THRUST BEARING,0.003"
|---P40-05-700 0025 PUMP ASSEMBLY,OIL,100GPM,TUTHILL
|---P40-14-219 0026 SCREW,CAP,WORM HOUSING,RIGHT-HAND
|---P40-14-309 0027 GEAR,WORM,SUB-ASSY,8.6:1 (HOLROYD),POWER-END ASSY
|---P40-14-328 0028 NUT-ELASTIC STOP-1/2-13NC-HVY-21NU-083
Removing the Ring Gear

1. Loosen four 1/2-13UNC bolts, cotter pin, 1-14NF nut in the middle, and
take down crosshead platen.
2. Remove worm drive disk with spline.
3. Remove the lock washer.
4. Remove the spline drive.
5. Check wear of thrust bearings and races of the gear support bearing by
prying up on the ring gear and measuring gear movement with a dial indicator.
Correct clearance is no more than 0.015 in.
6. Remove the thrust ring.
25
7. Remove the first thrust bearing and the race of the gear support bearing.
Inspect the thrust-bearing cage for evidence of rollers wearing through the
cage. Replace the bearing if wear is evident.
8. Check wear of the radial bearing and races of the gear-support bearing.
Measure the clearance between the bearing and the inner race with a 6-in long
feeler gauge. Acceptable clearance is no more than 0.020 in.
9. Remove the ring gear by using lifting eyes, a chain, and a hoist.
10. Remove the second thrust bearing of the gear-support bearing. Inspect the
thrust-bearing cage for evidence of rollers wearing through the cage. Replace
the bearing if wear is evident.
11. Remove the inside race and the second thrust race of the gear-support
bearing by using lifting eyes, a chain, and a hoist. Put tension on the chain and
heat the race. Be careful not to overheat any area of the race.
12. Remove the bearing support by using lifting eyes, a chain, and a hoist.
26
P40-14-400 RING GEAR(HOLROYD) SUBASSEMBLY
|---P40-14-241 0001 SCREW,CAP,SPLINE DRIVE-FLANGE
|---P40-14-202 0002 PIN,COTTER,1/8"x1 1/2",SPRING STEEL
|---P40-14-203 0003 NUT,HEX SLOT,1"-14NF,PL
|---P40-14-204 0004 WIRE,STOVE PIPE,19 GA,72" LONG
|---P40-14-205 0005 SPIDER,CRANKSHAFT THRUST RETAINER
|---P40-14-206 0006 BUSHING,SPIDER SPACER
|---P40-14-207 0007 SHIM,POSITIONING,CRANKSHAFT AXIAL,0.020"
|---P40-14-210 0010 COUPLING,CRANKSHAFT,SPLINE DRIVE
|---P40-14-211 0011 WIRE,STOVE PIPE,19 GA.,190" LONG
|---P40-14-212 0012 SCREW,CAP,RING,MOUNTING,GEAR CLAMP
|---P40-14-213 0013 WASHER,LEFT-HAND GEAR BEARING CLAMP
|---P40-14-214 0014 ROD,WELDING,L-61,1/8",95" LONG
|---P40-14-215 0015 CONTACTOR,NO. 8,128-B RELIANCE
|---P40-14-216 0016 FLANGE,GEAR SPLINE DRIVE
|---P40-14-219 0019 SCREW,CAP,WORM HOUSING,RIGHT-HAND
|---P40-14-220 0020 RING,THRUST,GEAR BEARING
|---P40-14-221 0021 SHIM,CLEARANCE,GEAR SUPPORT BEARING,0.003"
|---P40-14-225 0025 BEARING,GEAR SUPPORT
|---P40-14-426 0026 GEAR,RING,SUB-ASSY,8.6:1 (HOLROYD),POWER-END ASSY
|---P40-14-427 0027 GEAR,RING,SUB-ASSY,8.6:1 (HOLROYD),POWER-END ASSY
|---P40-14-229 0029 LUG,GEAR BEARING CLAMP,RIGHT-HAND
|---P40-14-211 0031 WIRE,STOVE PIPE,19 GA.,190" LONG
|---P40-14-232 0032 SCREW,HEX SOCKET,1/2"-13NCx1 1/4"
|---P15-36-014 0033 WASHER,LOCK,1/2" INT SHAKEPROOF
|---P40-14-234 0034 SUPPORT,BEARING,RING GEAR
|---P40-14-235 0035 SHIM,POSITIONING,GEAR SIDE,0.003"
|---P40-14-240 0040 STUD,FLANGED,CRANKSHFT THRUST
|---P40-14-241 0041 SCREW,CAP,SPLINE DRIVE-FLANGE
|---V06-50-322 0043 WASHER,SPRING LOCK,STEEL,1/2"ID
27
Attentionright drive pump has one more parts check ringP40-14-201.List
picture below:
28
Removing the Crankshaft
1. This procedure must operate after taking down worm component.
2. Check the four main bearings. The outer mains are accessible from
the ends. The inboard mains, as well as the outboard mains, are
accessible through the access holes in the back of the case. If the
entire length of a 6"0.012"[150 X 0.3mm] feeler gauge fits between
the roller and the outer race of any of the main bearings, replace all the
main bearings. (Make a reference to crankshaft repair later).
3. Remove the injector, follow the guidelines below. Lifting pump and
turnover, make a upturned worm case
4. Remove flange bolt (23), inner spline platen.
5. Lift slightly crankshaft. Attention: Do not damage bearing.
29
P40-12-000 CRANKSHFT SUBASSEMBLY,POWER-END ASSEMBLY
|---P40-12-001 0001 NUT,ELASTIC STOP,1/4-28NF-LT,21NE-48
|---P40-12-002 0002 WASHER,FLAT,3/16",WI-PL
|---P40-12-003 0003 WASHER,STAT-O-SEAL,1/4"7100-1/4"
|---P40-12-004 0004 CUP,SEAL RETAINER,CRANKSHFT ROD
|---P40-12-006 0006 SCREW,CAP,SEAL RETAINER
|---P40-12-007 0007 PLUG,CRANKSHFT ROD JOURNAL
|---P40-12-008 0008 CRANKSHFT ASSEMBLY
|---P40-12-009 0009 WASHER,RETAINER,INNER RACE,HEAVY-DUTY MAIN BEARING
|---P40-12-010 0010 NUT,SELF-LOCKING,1/2"-13NC,PL
|---X20-08-595 0011 HHCS,.500-13UNCx3 1/2"LONG,SAE GRADE 5
|---P40-12-012 0012 WASHER,BEARIGN RETAINER,FORGED
|---P40-12-013 0013 SCREW,HEX CAP,1/2"-13NCx2 3/4",PL
|---P40-12-014 0014 BEARING,MAIN OUTBOARD,17"O.D.X13 1/4"I.D.X1 13/16"W,STANDARD
|---P40-12-015 0015 WASHER,OUTER RACE,CRANKSHFT,MAIN BEARING
|---X20-08-509 0016 HHCS,.375-16UNCx1 1/4"LONG
|---X20-05-052 0017 SHCS,0.312-18 UNC x 1.00"
|---P15-01-012 0018 NUT,ELASTIC STOP,5/16" 18NC
|---P40-12-019 0019 BEARING,MAIN INBOARD,17"O.D.X13 1/4"I.D.X2 3/4"W,STANDARD
|---P40-12-020 0020 SCREW,CAP,INBOARD BEARING RACE RETAINER
|---P40-12-021 0021 RING,RETAINER,RIGHT-HAND
|---P40-12-022 0022 WASHER,OUTER RACE
|---P40-12-016 0023 SHCS,1/2"-13NCx3",FULL THREAD,W/HOLES
30
LUBRICATING OIL INJECTION COMPONENT OF CRANKSHAFT
Part # Item Qty Description
X20-28-509 0036 4.0000 WASHER,LOCK,5/16"
X20-08-576 0037 4.0000 HHCS,5/16"-18UN 1"LONG SAE GRADE 5
P15-12-031 0038 1.0000 NUT,63121 THREAD PROTECTOR,7/8"-18UNS W
P15-11-031 0039 1.0000 GASKET,DRIVE ADAPTER,CAP,GALLON COUNTER
P15-10-031 0040 1.0000 INJUCTOR,OIL,CRANKSHAFT,W/#20 HOSE ADAPTER
P15-08-031 0041 1.0000 RING,RETAINING-N5000 156 H
P15-09-031 0042 1.0000 GASKET,INJUCTOR,CRANKSHAFT,OIL W/#20 ADAPTER
P15-04-031 0043 1.0000 RING,SEAL
P15-03-031 0044 1.0000 BUSHING,MAGNETIC,SEAL INSULATOR & COUNTER DRIVE
P15-01-031 0046 1.0000 SHAFT,DRIVE,HT-400B,GALLON COUNTER
P15-05-031 0047 1.0000 SEAL,MAGNETIC,SHAFT,MSC,65152 REV B
000P569120 0055 1.0000 O-RING,NITRILE 90 DURO #120,PEROXIDE CURED
31
Removing the Slides
1. Remove the long crosshead cover.
2. Remove the short crosshead cover.
3. Adopt number methods used in ram and number the nearest worm NO.1.
4. Remove the baffle.
5. Making sure again that three crosshead oil nozzles and assorted tube,
linkers have been taken down.
6. Take down fixed bolt in the outside bracing of No.1, No.2 slides.
7. Remove bracings on the left and right of No.2 slide.
8. Remove slides and washer that behind it, and put them match along with
ram crosshead and its slides.
32
33
P40-13-000 CONNECTING ROD SUBASSEMBLY,POWER-END ASSEMBLY
|---P40-13-001 0001 WIRE,STOVE PIPE,19 GA,144"LONG
|---P40-13-002 0002 CONNECTING-ROD SUBASSEMBLY,POWER-END ASSEMBLY
|---P40-13-003 0003 DOWEL,CONNECTING-ROD CAP
|---P40-13-004 0004 BEARING,BOTTOM,CONNECTING-ROD
|---P40-13-005 0005 BEARING,TOP,CONNECTING-ROD
|---P40-13-006 0006 SCREW,CAP,RETAINING,CROSSHEAD PIN
|---P40-13-007 0007 WASHER,DISHED
|---P40-13-008 0008 KEY,CROSSHEAD PIN
|---P40-13-009 0009 PIN,CROSSHEAD
|---P40-13-010 0010 NUT,ELASTIC STOP,5/16"-24NF,LT,21NE-054
|---P40-13-011 0011 SLIDE,TIP CROSSHEAD
|---P15-13-013 0012 SCREW,FH CAP,1/4" 20NCx5/8"
|---P40-13-013 0013 SHOE TOP,CROSSHEAD
|---P40-13-014 0014 SHIM,CROSSHEAD SHOE,TOP,0.003"
|---P40-13-018 0018 CROSSHEAD,MACHINED
|---P40-13-019 0019 SHOE BOTTOM,CROSSHEAD
|---P40-13-020 0020 SLIDE-BOTTOM,CROSSHEAD
|---P40-13-021 0021 SHIM,CROSSHEAD SLIDE,0.002"
|---P40-13-024 0024 FOOT,RIGHT-HAND CROSSHEAD SLIDE CLAMP
|---P40-13-025 0025 SCREW,CROSSHEAD SLIDE CLAMP
|---P40-13-026 0026 FOOT,LIFT-HAND CROSSHEAD SLIDE CLAMP
|---P40-13-027 0027 SCREW,1/4"-20NCx1",CUP PT,HEX SOCKET,PL
|---P40-13-028 0028 SCREW,1/4"-20NCx1/4",CUP PT,HEX SOCKET,PL
|---P40-13-029 0029 CLAMP,OUTBOARD,CROSSHEAD SLIDE
|---P40-13-030 0030 SHIM,BOTTOM CROSSHEAD,0.005"
|---P40-13-031 0031 SHIM,BOTTOM CROSSHEAD,0.010"
34
SPACER ASSEMBLY,WITH STEEL PLATES AND TUBES
35
P40-15-120(*)
P40-15-100 (**) SPACER ASSEMBLY,WITH STEEL PLATES AND TUBES
P40-15-101(***)
P40-15-143*
P40-15-140** 0001 3.0000 ADAPTER-PUSH ROD-TWO PIECC NOSE
P40-15-144 (***)
P40-15-102 0002 3.0000 RETAINER,PUSH ROD,TWO-PIECE NOSE
P40-15-104 0004 3.0000 PUSH ROD,TWO-PIECE,L-SPACER,HT-400
P40-15-105 0005 3.0000 TIE ROD,PUSH ROD,L-SPACER,HT-400
P40-15-106 0006 1.0000 GUARD,L-4 AND L-3 SPACER
P40-40-614 0007 12.0000 NUT,1"-14NF,INTERNAL WRENCHING,1.03" THREAD LENGTH
P40-15-108 0008 12.0000 TUBE,FRAME,L-4 SPACER
P40-15-109 0009 3.0000 RING,RETAINING,437 INT,.4378-SPEC
P40-15-110 0010 3.0000 KIT,SEAL,WIPER,3 3/8-IN
P40-15-111 SCREW,SHOULDER,5/16-IN 18UNC x 1/2-IN HEX SOCKET,3/8-IN DIA

0011 9.0000
X20-08-048 (*)(**) NUT,1"-14NF,INTERNAL WRENCHING,1.03" THREAD LENGTH
P40-11-008 0012 9.0000 WASHER,FLAT,5/16",WI,PL
P40-15-113 0013 3.0000 GLAND,WIPER,T/URETHANE,L-4 AND L-3 SPACER
X20-08-576 0015 6.0000 HHCS,5/16"-18UN 1"LONG SAE GRADE 5
X20-28-509 0016 6.0000 WASHER,LOCK,5/16"
P40-15-117 0017 12.0000 STUD,ATTACHING,FE TO PE L-4 AND L-3 SPACER
P40-15-118 0018 1.0000 PLATE,POWER END,L-4 SPACER
000P569242 (***) 0019 3.0000 O-RING,NITRILE 90 DURO #242,PEROXIDE CURED
NOTICE: THE PART MARED

(*) BELONGS TO 3 3/8 PUMP,
(**) BELONGS TO 4PUMP,
(***) BELONGS TO 4 1/2PUMP.
36
Maintenance and Inspection
Clean all parts of the power end before assembly. Clean the case with a
pressure hose by using a grease-cutting additive. Clean the heat exchanger
core in a solvent such as naphtha. Remove material lodged in the fins with
blasts of compressed air. Clean the bearings in new solvent and dry them with
clean compressed air. Clean all other parts in solvent and allow them to dry.
Discard the gaskets and replace O-rings and seals that are in poor condition.
Power-end maintenance and inspection

1. After you clean the case, inspect it for cracks, especially around the front
face above and below the crosshead bores. If a large magnetic particle
inspection machine is available, use it to do the inspection. If cracks are
found, do not attempt to gouge and reweld the structural welds. Rewelding
deforms the case and causes the cracking problem to worsen. Replace
severely cracked cases.
2. Measure the three crosshead bores, which have four braces in the top bore
and four in the bottom. Measure all of them with a micrometer. If the bores
are oversized[ greater than 9.750 to 9.760 in. (24.765 to 24.790 cm), or out
of parallel[ the braces vary more than 0.044 in.(0.01 cm) from one anther],
either replace or rebore them for oversized slides. ( SJS accept case
customizing)
3. If any of the fluid-end attaching studs are galled, remove them with a pipe
wrench. If a tapped hole in the case becomes galled, retap it or drill, tap,
and install helicoil inserts. Do not perform helicoil repairs on high-horse
units. Use a maximum of three helicoils. Do not helicoil the four outer
corner threads.
4. Use a stud installer to install new studs. Use thread lubricant on the
threads.
Oil-Pump Maintenance
Inspect the oil-pump drive shaft. If it is rounded, replace the oil pump. If the
shaft is in good condition, check the pump action. Submerge the pump in
solvent and turn the shaft by hand. If the shaft does not turn freely or if the
pump does not circulate the solvent, check for internal damage. Save the
gaskets; they serve as shims to adjust clearance in the pump.
Power import shaft seal

Engine wheel box pass power to pump by worm input shaft. Worm shaft of
400 adopt 1800 series drive flange. Worm case has oil storage, so flange is
37
matched import seal. Follow the guidelines below to know how to replace
shaft seal:
1. Loosen hexagon bolt 3/8"-16NCx1 1/4" in the flange, and take down link
flange.
2. Loosen inner hexagon bolt 3/8"-16NCx1 1/4", and take down oil seal block,
gasket. Do not take down rolling bearing block.
3. Crack old oil seal. Attention: Do not break oil seal block. Use 5.4 section
plastic block install oil seal. Caution: oil seals openings toward fluid-end.
4. Daub a round lubricant in the new installed oil seal openings, and install
new oil seal gasket, oil seal block.
5. Install linked flange. Fix it by lock gasket and nut. Bend horn that used for
loosening steel in order to fasten nut.
COMPANIONFLANGESUBASSEBLY
P40-14-600 (PNENUMATICALLY DRIVEN LUBRICATOR)
|---P40-14-501 0001 1.0000 FLANGE,COMPANION,6 1/6",1-951 SPICER
|---P40-14-502 0002 1.0000 WASHER,WORM YOKE RETAINER
|---P40-14-503 0003 1.0000 WASHER,LOCK,WORM YOKE RETAINER
|---X20-08-509 0004 2.0000 HHCS,.375-16UNCx1 1/4"LONG
|---P40-14-101 0005 4.0000 SCREW 3/8"-16NCx1 1/4"

|---V06-68-473 0006 4.0000 WASHER 3/8"
|---P40-14-103 0007 1.0000 SEAL SEAT
|---P40-14-104 0008 1.0000 SEAL 53x7448,FL,4"B x5 1/2"ODx1/2"W
38
Bypass maintenance
Recommend bypass overflow pressure is 100PSI. Adjusting compression of
spring in order to keep pressure.
400 operate slowly, so worm turn slowly. Pump operates by worm, so output
reduces. All lubricant flow into major vitta, crankshaft, crosshead etc when
bypass valve turn off.
400 operate fast, so worm turn fast and pump give rise to overpressure. Low
temperature or high density lubricant also could lead to overpressure. At this
time, open bypass and overflow right amount of oil could recover pressure.
Overflow oil by bypass could help cooling and smoothing worm.
Bypass links with two upright filters. One is rough filtration, the other is
precision filtration. If indicator dial in the filtration indicate yellow, please clean
filtration.
P40-05-216 BODY,VALVE,BYPASS,SCHROEDER OIL SYSTEM
P40-05-201 1 SPRING,BYPASS,OIL PRESSURE 80~100PSI
P40-05-211 2 SCREW,ADJUST,BYPASS,SCHROEDER OIL SYSTEM
P40-05-213 3 CAP,BY-PASS,SCHROEDER OIL SYSTEM
P40-05-214 4 GASKET,CAP,SCREW,BYPASS,SCHROEDER
P40-05-215 5 BALL,STEEL,2",CHROME STEEL,GRADE 50
P40-05-212 6 BODY,ASSY,VALVE,BYPASS,SCHROEDER OIL SYSTEM
P40-05-206 7 MANIFOLD,OIL STRAINER AND FILTER,MACHINED
P40-05-420 8 FILTER,OIL,ELEMENT,25M
P40-05-410 9 FILTER,OIL,ELEMENT,25M
39
FLUID-END, TPH400,ASSY.
FLUID-END,3 3/8",TPH400,ASSY.
P40-33-000(*) FLUID-END,3 3/8",TPH400,ASSY, LEFT-HAND
P40-33-001(**) FLUID-END,3 3/8",TPH400,ASSY, RIGHT-HAND
DISCHARGE VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4"

P40-40-100 0001 3.0000
FLUID-END ASSY
SUCTION VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4"

P40-40-200 0002 3.0000
FLUID-END ASSY
P8T0009337 0003 3.0000 PACKING,SPS,ASSY,3.375,TPH400
P40-33-410 0004 3.0000 WIPER GLAND SUBASSEMBLY,3 3/8-IN FLUID END ASSEMBLY
PLUNGER SUBASSEMBLY,SHORT TIE-BOLT AND PLUNGER USED

P40-33-530 0005 3.0000
W/L-SPACER,3 3/8"
P40-08-010(*)
0006 1.0000 SUCTION PIPE SUBASSEMBLY
P40-08-011(**)
FLUID-END SECTION,SUBASSEMBLY W/TWO-PIECE PACKING NUT AND

P40-33-700 0007 1.0000
THREE TOP TIE-BOLT,3 3/8"
P40-33-600 0008 1.0000 BLANK FLANGE, 3 3/8", TPH400
P40-33-620(*)
0009 1.0000 FLANGE ASSEMBLY,LIFT-HAND, 3 3/8"
P40-33-610(**)
NOTICE: THE PART MARKED (*) BELONGS TO LEFT HAND DRIVE PUMP, THE PART
MARKED (**) BELONGS TO RIGHT HAND DRIVE PUMP
40
FLUID-END, 4,TPH400,ASSY.
P40-40-000(*)
P40-40-001(**) FLUID-END,4",TPH400,ASSY.
DISCHARGE VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4"

P40-40-100 0001 3.0000 FLUID-END ASSY
SUCTION VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4" FLUID-END

P40-40-200 0002 3.0000
ASSY
WIPER GLAND SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4" FLUID-END

P40-40-410 0004 3.0000
ASSY
P40-40-530 0005 3.0000 SHORT TIE-BOLT AND PLUNGER,USED W/ L-SPACER
P40-08-010(*)
0006 1.0000 SUCTION PIPE SUBASSEMBLY
P40-08-011(**)
FLUID-END SECTION SUBASSEMBLY W/TWO-PIECE PACKING NUT AND

P40-40-700 0007 1.0000
THREE TOP TIE-BOLT
P40-40-600 0008 1.0000 FLANGE ASSEMBLY W/TWO-PIECE PACKING NUT
P40-40-620(*)
0009 1.0000 FLANGE ASSEMBLY ,W/TWO-PIECE PACKING NUT
P40-40-610(**)
FLUID-END, 4 1/2,TPH400,ASSY.
P40-44-000(*)
FLUID-END,4 1/2",TPH400,ASSY.,
P40-44-001(**)
P40-44-100 0001 3.0000 DISCHARGE VALVE SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
P40-44-200 0002 3.0000 SUCTION VALVE SUBASSEMBLY,4 1/2" FLUID-END ASSEMBLY
P40-44-410 0004 3.0000 WIPER GLAND SUBASSEMBLY,4 1/2" FLUID ENDASSEMBLY
P40-44-530 0005 3.0000 PLUNGER SUBASSEMBLY, 4 1/2" FLUID END ASSEMBLY
P40-08-010(*)
0006 1.0000 SUCTION PIPE SUBASSEMBLY,LEFT-HAND
P40-08-011(**)
P40-44-700 0007 1.0000 FLUID END SECTION SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
P40-40-600 0008 1.0000 FLANGE ASSEMBLY W/TWO-PIECE PACKING NUT
P40-40-620(*)
0009 1.0000 FLANGE ASSEMBLY,LEFT-HAND,W/TWO-PIECE PACKING NUT
P40-40-610(**)
41
DISCHARGE VALVE SUBASSEMBLY, FLUID END ASSEMBLY
DISCHARGE VALVE SUBASSEMBLY W/TWO-PIECE PACKING NUT, 3 3/8" AND 4

FLUID-END ASSY
P40-33-100(*) DISCHARGE VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT,4" AND 3

P40-40-100(**) 3/8 FLUID-END ASSY
P40-40-706
0001 1.0000 RETAINER,COVER,MACH,4" FLUID-END ASSY
P40-40-101
P40-40-102 0002 1.0000 COVER,SHORT,DISCHARGE,NO.4 DOUBLE,GUIDED VALVE
P40-40-103 0003 1.0000 GASKET,NO.4 DISCHARGE VALVE AND CYLINDER HEAD COVER,4 1/2"
P40-40-104(*)
0004 1.0000 RING,SPACER,NO.4 DISCHARGE VALVE AND CYLINDER HEAD COVER,
P40-44-709(**)
P40-40-112 0005 2.0000 INSERT,FOR TWO-PIECE BUSHING,NO.4 VALVE GUIDE
P40-40-106 0006 1.0000 SPRING,VALVE,36LB/IN
P40-40-107 0007 1.0000 VALVE,FRAC,3 3/8"
P40-40-108 0008 1.0000 INSERT,POLYURETHANE,NO.3 FRAC VALVE, STANDARD SERVICE
P40-40-109 0009 1.0000 SEAT,VALVE,TAPERED,NO.3 FRAC
P40-40-111 0011 1.0000 RETAINER,GUIDE BUSHING,3 3/8"x1/8"
NOTICE: THE PART MARKED (*) BELONGS TO 3 3/8 PUMP, THE PART MARKED (**)
42
BELONGS TO 4 PUMP
DISCHARGE VALVE SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY

P40-44-100 DISCHARGE VALVE SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
P40-40-101 0001 1.0000 RETAINER,COVER,MACH,4" FLUID-END ASSY
P40-40-102 0002 1.0000 COVER,SHORT,DISCHARGE,NO.4 DOUBLE,GUIDED VALVE
RING,SPACER,NO.4 DISCHARGE VALVE AND CYLINDER HEAD COVER, 4

P40-44-709 0004 1.0000 1/2"
P40-44-106 0006 1.0000 SPRING,VALVE,25LB/IN,STAINLESS,4-IN.AND 4 1/2-IN
P40-44-107 0007 1.0000 VALVE,FRAC NO.4 FRAC
P40-44-108 0008 1.0000 INSERT,POLYURETHANE,NO.4 FRAC VALVE, STANDARD SERVICE
P40-44-109 0009 1.0000 SEAT,VALVE,TAPERED NO.4 FRAC
P40-44-111 0011 1.0000 RETAINER,GUIDE BUSHING,NO.4 FRAC VALVE,L/TAPERED AD
SUCTION VALVE SUBASSEMBLY, FLUID-END ASSEMBLY
43
SUCTION VALVE SUBASSEMBLY W/ TWO-PIECE PACKING NUT, 3 3/8" AND 4
FLUID-END ASSY(NOT COMPLETED)
SUCTION VALVE SUBASSEMBLY W/ TWO-PIECE

P40-40-200 PACKING NUT,4" AND 3 3/8 FLUID-END ASSY(NOT COMPLETED)
P40-40-106 0006 1.0000 SPRING,VALVE,36LB/IN
P40-40-107 0007 1.0000 VALVE,FRAC,3 3/8"
INSERT,POLYURETHANE,NO.3 FRAC VALVE,

P40-40-108 0008 1.0000 STANDARD SERVICE
P40-40-109 0009 1.0000 SEAT,VALVE,TAPERED,NO.3 FRAC
P40-40-111 0011 1.0000 RETAINER,GUIDE BUSHING,3 3/8"x1/8"
P40-14-202 0013 2.0000 PIN,COTTER,1/8"x1 1/2",SPRING STEEL
P40-40-214 0014 1.0000 SPRING,LOCK,NO.3 SUCTION STOP
P40-40-215 0015 1.0000 BOOT,SUCTION STOP,NO.3,NO.4 & NO.5 VALVE
P40-40-216 0016 1.0000 RETAINER,STOP AND SPRING,NO.3 SUCTION VALVE
44
SUCTION VALVE SUBASSEMBLY,4 1/2" FLUID-END ASSEMBLY
P40-44-200 SUCTION VALVE SUBASSEMBLY,4 1/2" FLUID-END ASSEMBLY
P40-44-106 0006 1.0000 SPRING,VALVE,25LB/IN,STAINLESS,4-IN.AND 4 1/2-IN
P40-44-107 0007 1.0000 VALVE,FRAC NO.4 FRAC
INSERT,POLYURETHANE,NO.4 FRAC VALVE, STANDARD

P40-44-108 0008 1.0000 SERVICE
P40-44-109 0009 1.0000 SEAT,VALVE,TAPERED NO.4 FRAC
P40-44-111 0011 1.0000 RETAINER,GUIDE BUSHING,NO.4 FRAC VALVE,L/TAPERED AD
P40-44-213 0013 1.0000 SPRING,LOCK,NO.4 SUCTION STOP
P40-40-215 0014 2.0000 BOOT,SUCTION STOP,NO.3,NO.4 & NO.5 VALVE
P40-44-215 0015 1.0000 RETAINER,STOP AND SPRING,NO.4 SUCTION VALVE
B01-15-003 0016 1.0000 PIN,COTTER,5x35 GB91-86
45
PACKING,SPS,ASSY, TPH400
PACKING,SPS,ASSY,3 3/8,TPH400
P8T0009337 PACKING,SPS,ASSY,3.375,TPH400
P803370125 0001 1.0000 PACKING,SPS,JUNK RING,3.375x4.375x0.125
P902503370 0002 1.0000 PACKING,SPS,HEADER RING,3.375x4.375
P907503370 0003 1.0000 PACKING,SPS,V4 RING,3.375x4.375
P904503370 0004 1.0000 PACKING,SPS,FEMALE ADAPTER,3.375x4.375
PACKING,SPS,LANTERN
P833371980 0005 1.0000 RING,3.375x4.375x1.981
O-RING,NITRILE 90 DURO #243,PEROXIDE

000P569243 0006 1.0000 CURED
P905503370 0007 1.0000 PACKING,SPS,WS SEAL,3.375x3.875x0.413
P8A0009337 0050 0.0000 PACKING,SPS,REPAIR KIT A,3.375,TPH400
PACKING,SPS,ASSY,4,TPH400
PACKING,SPS,LANTERN
P834002360 0005 1.0000 RING,4.000x5.000x2.361

000P569248 0006 1.0000 CURED
P905504000 0007 1.0000 PACKING,SPS,OL SEAL,4.000x4.500x0.413
46
PACKING,SPS,ASSY,4 1/2,TPH400
PACKING,SPS,LANTERN
P834502360 0005 1.0000 RING,4.500x5.500x2.361

000P569252 0006 1.0000 CURED
P905504500 0007 1.0000 PACKING,SPS,OL SEAL,4.500x5.000x0.413
WIPER GLAND SUBASSEMBLY, FLUID ENDASSEMBLY
47
WIPER GLAND SUBASSEMBLY,3 3/8-IN FLUID END ASSEMBLY
P40-33-410 WIPER GLAND SUBASSEMBLY,3 3/8-IN FLUID END ASSEMBLY
P40-33-411 0001 1.0000 NUT,PACKING ADJUSTMENT,3 3/8"
P40-15-109 0002 0.0000 RING,RETAINING,437 INT,.4378-SPEC
P40-33-413 0003 0.0000 SEAL,WIPER,3 3/8-IN., TPH400, PE-DISOGRIN
P40-33-414 0004 1.0000 SLEEVE,WIPER GLAND,3 3/8-IN.
P40-40-415 0005 1.0000 PIN,GROOVE,1/2"x1 1/4",TYPE 5,SAE 6150, RC50-55
WIPER GLAND SUBASSEMBLY,4" AND 4 1/2" FLUID ENDASSEMBLY

P40-40-410(*)
WIPER GLAND SUBASSEMBLY,4 1/2" FLUID ENDASSEMBLY
P40-44-410(**)
P40-44-411 0001 1.0000 NUT,PACKING ADJUSTMENT,4 1/2"
P40-40-412 0002 0.0000 RING,RETAINING,RR-550,INT,SPIROLOX
P40-40-413(*)
0003 0.0000 DIAPHRAGM OIL SEAL
P60-44-801(**)
P40-40-414 0004 1.0000 SLEEVE,WIPER GLAND,4"
P40-40-415 0005 1.0000 PIN,GROOVE,1/2"x1 1/4",TYPE 5,SAE 6150, RC50-55
NOTICE: THE PART MARKED (*) BELONGS TO 4 PUMP, THE PART MARKED (**)
BELONGS TO 4 1/2 PUMP
48
TIE-BOLT AND PLUNGER SUBASSEMBLY
PLUNGER SUBASSEMBLY,SHORT TIE-BOLT AND PLUNGER USED W/L-SPACER,3

3/8"
PLUNGER SUBASSEMBLY,SHORT TIE-BOLT AND

P40-33-530 PLUNGER USED W/L-SPACER,3 3/8"
P40-33-511 0001 1.0000 NOSE,PLUNGER,MACHINED,3 3/8"
P40-33-512 0002 1.0000 SEAL ASSEMBLY,PLUNGER NOSE,3 3/8"
P40-33-533 0003 1.0000 PLUNGER,HARD SURFACED,L-SPACER,3 3/8"
P40-40-534 0004 1.0000 TIE ROD,L-SPACER,PLUNGER
SHORT TIE-BOLT AND PLUNGER,USED W/ L-SPACER 4

P40-40-530 SHORT TIE-BOLT AND PLUNGER,USED W/ L-SPACER
P40-40-511 0001 1.0000 NOSE,PLUNGER,MACHINED
P40-40-512 0002 1.0000 SEAL ASSEMBLY,PLUNGER NOSE
P40-40-533 0003 1.0000 PLUNGER,HARD SURFACED,L-SPACER
49
PLUNGER SUBASSEMBLY, 4 1/2" FLUID END ASSEMBLY
P40-44-530 PLUNGER SUBASSEMBLY, 4 1/2" FLUID END ASSEMBLY
P40-44-511 0001 1.0000 NOSE,PLUNGER,MACHINED,4 1/2"
P40-44-512 0002 1.0000 SEAL ASSEMBLY,PLUNGER NOSE,4 1/2"
P40-44-533 0003 1.0000 PLUNGER,SHORT TIE BOLT,HARD SURFACED, 4 1/2"
50
FLANGE ASSEMBLY W/TWO-PIECE PACKING NUT
BLANK FLANGE, 3 3/8", TPH400

P40-33-600 BLANK FLANGE, 3 3/8", TPH400
P40-33-611 0001 1.0000 BLANK FLANGE,DISCHARGE,RIGHT OUTLET,3 3/8" -IN.
P40-33-711 0002 1.0000 SEAL,DISCHARGE PASSAGE, 2 1/2" OD
P40-33-627 0003 2.0000 STUD,FLUID-END TO THIN PLATE DISCHARGE FLANGE
BLANK FLANGE, 4"AND 4 1/2", TPH400

P40-40-600 FLANGE ASSEMBLY W/TWO-PIECE PACKING NUT
FLANGE,DISCHARGE,F/OUTLET,2 1/2" THICK USE STANDARD TOP

P40-40-611 0001 1.0000 TIE-BOLT W/BLANK FLANGE
P40-40-612 0002 1.0000 SEAL,DISCHARGE PASSAGE,3 3/8"OD
P40-44-627 0003 0.0000 STUD,DISCHARGE FLANGE,6"
51
FLANGE ASSEMBLY,LEFT-HAND,W/TWO-PIECE PACKING NUT
52
FLANGE ASSEMBLY, LEFT -HAND, 3 3/8"
P40-33-620 FLANGE ASSEMBLY,LEFT-HAND, 3 3/8"
P40-33-626 0001 1.0000 FLANGE,DISCHARGE ELL,20000PSI WECO THREAD LEFT-HAND
FLANGE ASSEMBLY,LEFT-HAND, 4"AND 4 1/2",

P40-40-620 FLANGE ASSEMBLY,LEFT-HAND,W/TWO-PIECE PACKING NUT
P40-40-626 0001 1.0000 FLANGE,DISCHARGE,LEFT-HAND,3" OUTLET
F4P-10-258 0005 1.0000 SEAL,RING,3" FIG 1502 UNION
F4P-10-229 0006 1.0000 SEAL,RING,2",FIG 1502,1002,602,402,UNION
53
FLUID END SECTION SUBASSEMBLY
54
FLUID-END SECTION,SUBASSEMBLY W/TWO-PIECE PACKING NUT AND THREE TOP
TIE-BOLT,3 3/8"
FLUID-END SECTION,SUBASSEMBLY W/TWO-PIECE PACKING NUT AND THREE

P40-33-700 TOP TIE-BOLT,3 3/8"
P60-34-001 0001 1.0000 NAMEPLATE
P40-40-702 0002 0.0000 GUARD,LUBE LINE
P40-40-703 0003 0.0000 CLAMP,HOSE,1"x1 1/2",MURRAY,AERO SEAL
P40-40-704 0004 2.0000 NUT,TOP-TIE-BOLT,RC30-24,W/TAPERED THREADS
P40-40-705 0005 1.0000 BOLT,TOP-TIE,3 DISCHARGE FLANGE,6"
P40-40-706 0006 3.0000 RETAINER,COVER,3 3/8"
P40-40-707 0007 3.0000 COVER,CYLINDER HEAD,3 3/8"
P40-40-709 0009 3.0000 RING,SPACER,NO.3 DISCHARGE VALVE AND CYLINDER HEAD COVER, 3 3/8"
FLUID-END SECTION,MACHINED 3 3/8",BORED FRONT PACKING SLEEVE HAS

P40-33-710 0010 3.0000
TAPERED SEAT BORES.DOES NOT USE
P40-33-712 0012 0.0000 SPACER.INNER DISCHARGE PASSAGE,3 3/8" FLUID END
P40-44-714 0014 2.0000 NUT,ELASTIC STOP,3/4"-16NF
P40-44-715 0015 1.0000 BOLT,BOTTOM TIE ,CYLINDER
X20-08-537 0017 12.0000 HHCS,.625-11UNCx1 1/4",SAE GR8,PLATED
P40-44-718 0018 2.0000 STUD,7/8"-9NCX4 3/4"
P40-40-719 0019 0.0000 WASHER,HARDENED,2 3/4"ODx1.43"ID,F/TOP-TIE-BOLT
P40-33-720 0020 0.0000 SLEEVE,FLUID-END,TPH400,3 3/8"
55
FLUID END SECTION SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
P40-44-700 FLUID END SECTION SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
P60-34-001 0001 1.0000 NAMEPLATE
P40-40-702 0002 0.0000 GUARD,LUBE LINE
P40-40-101 0006 3.0000 RETAINER,COVER,MACH,4" FLUID-END ASSY
P40-44-707 0007 3.0000 COVER,CYLINDER HEAD, 4" AND 4 1/2"
FLUID-END SECTION,MACHINED 4"&4 1/2",TPPERED VALVE HAS

P40-44-710 0010 3.0000
TAPERED SEAT BORES.DOES NOT USE TAPERED ADAPTER
P40-40-712 0012 2.0000 SPACER.INNER DISCHARGE PASSAGE,3 3/8"OD
P40-44-713 0013 8.0000 CAP PLUG,PLASTIC,3/4-IN. PLUG,CLOVER
P40-44-714 0014 2.0000 NUT,ELASTIC STOP,3/4"-16NF
P40-44-715 0015 1.0000 BOLT,BOTTOM TIE ,CYLINDER
P40-44-718 0018 2.0000 STUD,7/8"-9NCX4 3/4"
P40-44-720 0020 0.0000 SLEEVE,FLUID-END,HT-400,4 1/2"
P40-44-725 0025 3.0000 PLUG,PIPE,1/16"NPT MALE
FLUID-END SECTION,MACHINED 4"&4 1/2",TPPERED VALVE HAS

P40-44-721 0030 0.0000
TAPERED SEAT BORES.DOES NOT USE TAPERED ADAPTER
56
FLUID-END SECTION SUBASSEMBLY

P40-40-700 W/TWO-PIECE PACKING NUT AND THREE TOP TIE-BOLT
P60-34-001 0001 1.0000 NAMEPLATE
P40-40-702 0002 0.0000 GUARD,LUBE LINE
P40-40-706 0006 3.0000 RETAINER,COVER,3 3/8"
P40-40-707 0007 3.0000 COVER,CYLINDER HEAD,3 3/8"
FLUID-END SECTION,MACHINED 4",BORED FRONT PACKING SLEEVE

P40-40-710 0010 3.0000
HAS TAPERED SEAT BORES.DOES NOT USE TAPERED ADAPTER
P40-40-712 0012 2.0000 SPACER.INNER DISCHARGE PASSAGE,3 3/8"OD
FLUID END SECTION SUBASSEMBLY,4 1/2" FLUID END ASSEMBLY
57
P40-40-714 0014 2.0000 BOLT,TIE,HT-400,1" DIA.,FOR THREE TOP-TIE-BOLT
P40-44-718 0018 2.0000 STUD,7/8"-9NCX4 3/4"
P40-40-720 0020 0.0000 SLEEVE,FLUID-END
P40-40-721 0021 0.0000 O-RING,90D,4 3/4"x4 1/2"x1/8"
FLUID-END SECTION DISASSEMBLE
58
59
Attention:
Parts should purchase only from SJS. Similar purchased parts are out of use.
Follow the steps below to check bypass:

1. Remove the bypass from the power end.
2. Remove the cap and gasket from the bypass.
3. Remove the adjusting screw, spring, and position.
4. After you clean the assembly, inspect the position and the seat inside the
housing. If either is badly worn, replace the bypass as an assembly. If both are
in good condition, install the position.
5. Install the spring and adjustment screw. Temporarily set the tension on the
spring (and the pressure at which the valve opens) by running the adjustment
screw in completely. Later, check the setting with the pump in operation.
6. Install the cap and gasket. Be sure the gasket is in good condition.
7. Install the bypass. If the pump has an adjustable bypass, such as the
Schroeder system, follow procedures on Page 3-3 through 3-5.
Schroeder Oil System Maintenance

1. Drain the sump of both the three-element filter and the magnetic strainer.
2. Loosen the four-bolt flanges by attaching the sump to the Schroeder dirt
alarm heads, and allow the sumps to continue draining.
3. Remove the filter sump. Save the two connectors from between the
elementsSave the spring and spring plate located in the sump bottomAll
must be reused when the unit is reassembledDiscard the three disposable
elements
4. After the oil has drainedremove the magnetic-strainer sump
5. Unscrew the magnetic-strainer element from the dirt alarm head as a unit
Important: Do not take the magnetic strainer apartIt is extremely difficult to

reassemble
6Wash the magnetic strainer in a suitable solvent, such as naphthaand blow

debris out of it with compressed airSome small particles may remain on the
magnets inside the sleeve and screen, but they will not wash off into the oil
system
.7Install the magnetic strainer onto the dirt-alarm headfixing the Oring in
position with a coat of grease
8Thoroughly clean the short sump in solvent and install it on the strainer
Important: Do not switch the sumps or the oil will not be filtered properlyThe
elements are not interchangeable.
60
9Install three new filter elements in the long sumpMake sure the spring and
spring plate and the two element connectors are in placeLight pressure is
required on the sump bottom as flange bolts are inserted
Note: Some Schroeder filters are equipped with reusable filter elements made
of steel wire meshUse reusable filters only when disposable elements are not
availableUltrasonic equipment is required for cleaning these elements
Crankshaft and Main Bearings Maintenance

1Remove the three cups and the plug from the crankshaftWash the
crankshaft and the main bearings with new solventDry them with compressed
air
2Inspect the crankshaft
If the journals are badly scoredreplace or regrind the crank
If the journals are in good condition, measure them with a micrometer,
comparing readings from 4999 to 5000 in(12697 to 127 cm),the
diameter of new crankshaft journals(Subtract theundersizeddimension
0040 or 0080 in(010 or 020 cm) from this figure if the crankshaft
has been reground)Replace or regrind the crankshaft if any of the
journals are undersized more than 0006 in(O015 cm) or out-of-round
more than 0003 in. (0008 cm)Replace the crankshaft if cracks are
discoveredCracks are sometimes found radiating from the drilled oil
holes in the journals
3Examine clearances in the main bearings
If clearances in the main beatings are acceptable (Crankshaft, Page
4-4Step1)inspect the bearings for badly spalled rollersbroken cagesand
worn rivetsInspect the four main bearing races in the caseIf the races are
badly pittedreplace all the main bearings and their racesIf the races have
worn into the race washers that secure them, remove the races and check the
bores
If any of the bearings are faulty, replace all the main bearings
including the races still in the case
Race Replacement
1If the main bearings are faulty, remove the 12 race washers
2Drive the four races out either end of the case
3Measure the main bearing bores with a micrometerA bore is oversized if it
measures more than 17004 in(4319 cm)If a bore is oversizedthe race
has been turning in the case and not creeping(Races that creep prevent wear
from being concentrated in one area.) Make note of oversized boresSpecial
treatment is required
61
4Install two race washers on the inside of each of the bores for the inboard
main bearingsTurn the unworn side of the washers toward the bore
5Drive in the wide races for the inboard main bearingsone from either end
Seat them against the washersIf the main bearings are in good condition, use
the old racesIf main bearings are in poor condition, use new racesIf a bore
is oversized, secure the race with Loctite or an equivalent
Important: This procedure is for field repair ONLYOversized bores found in

shop facilities must be knurled to new dimensions
6Secure the inboard races by installing more race washers and install the
remaining race washers on the bores for the outboard main bearingsAgain,
turn the unworn side of the washers toward the bores
7Drive in the narrow races for the main bearingsseating them against the
washers
If oldstyle main bearings are being replaced with the new, heavy-duty main
bearings replace the washers and their screws (see Crankshaft
Subassembly)Turn the notched sides of the washers toward the races
If a bore is oversizedsecure the race with a threadlocking compound
Important: This procedure is for field repair ONLYOversized bores found in

shop facilities must be knurled to new dimensions
Main Bearing or Crank Replacement

1If the crankshaft andor main bearings (including the races)are in poor
condition, remove the retainer washers
2Turn the crankshaft so that the splined end is upHeat the main bearings
one at a timestarting at the bottomAs the bearings expand and drop from the
crankshaft, guide them off the bottom
Important:Do not reuse bearings that show signs of heat discolorationHeating

softens the steelHeated bearings may fail prematurely
3Install the three cups with the new Orings and plugThe plug goes into the
splined crankshaft endUse seal washers in addition to flat washers on both
ends of the screws
4Turn the crankshaft so the splined end is downHeat one of the outboard
(narrow)bearings to 200F(933)Install it on the bottom flangeworking it
down from the topSecure it with retainer washers
5Install the remaining three bearingsusing retainer washers as temporary
supportsInstall three washers on the underside of the bottom-most flange that
still does not have a bearingOn the flange, install an inboard (wide) bearing
that has been heated to 200F(933)Install more washers and another
62
inboard bearingInstall more washers and the remaining outboard bearingIf
replacing oldstyle(pre~1973)main bearings with new heavy-duty bearings
use undercut retainer washers and long screws on the inside of the outboard
bearings as described in Step 4
6After the bearings have cooled and contractedsecure them by installing the
remaining retainer washers.
Injector Seal and Bushing Maintenance

1If the crankshaft is old and has a liptype injector sealremove the seal
2Install a brass seal bushing, if the crankshaft is without oneClean the
bushing and the crankshaft bore with a thread cleaner and primerApply a high
strength retaining compound, such as Loctite 609to the outside diameter of
the bushing
3Install a new magnetic sealsmall end firstOil it liberally
4Secure the magnetic seal with the newstyle bushing and retaining ring
Crosshead and Connecting Rod Maintenance

Pin Bores
1Remove the dished washers from the crossheads and drive out the
pinsNumber the crossheads and pins to match the connecting rods they were
removed from
2Examine the pin bores of the crossheadsIf a crosshead is cracked or a
bore is worn larger than 3501 in(889 cm)replace the crossheadUse
magnetic particle inspection to locate small cracks
Shoes and Slides

1Inspect the shoesIf they are badly scored, replace them
2Inspect the slidesIf they are scored or corroded, replace them.
3When the new shoes are installedinstall the required number of shims
under each of the top(small)shoes to measure a thickness of0020 in. (0050
an)This measurement is preliminaryIf total shims required are more than
0025 in(006 cm)shim the top and bottom shoes equally
4 After the shoes are seated and secured check their fit If a
0003-in(0008-~rrl) shim fits between a shoe and crossheadreseat the
shoeBend or replace the shoes if all else fails
5Remove burrs and the lacquer coating from the shoesusing 120 emery
cloth.
63
Pins and Bushings
1Measure the crosshead pinspositioning the micrometer to measure
maximum wear
2Measure the crossheadpin bushingIf the clearance between the pin and
bushing is more than 0012 in(003 cm)replace the defective part.
To determine whether the pin or bushing is defectivecompare the OD of a

new pin [3499 to 3500 in(8887 to 8890 cm)] to the ID of a new bushing
installed in a connecting rod [3505 to 3506 in(8903 to 8905 cm)] If the
pump is being overhauled because of ageyou will likely have to replace
both the pin and the bushing
3Remove faulty bushings and install new ones by using the hydraulic press.
Rods and Bearings

1Check the connecting rodsReplace any rod under the following conditions
The rod has been blackened by heat
The rod is cracked(A dye penetrant process can be used to locate
cracks)
The dowel in the cap has been sheared and the bearing has been turning
in the connecting rod
2Check the seals between the ends of the oil tubes in old connecting rodsIf
the seal is faultyremove and discard the connecting rod and replace itFor
connecting rods with drilled oil holes, blow air through to be sure the drilled
passages are clear
3Check the bearingsReplace the bearings under the following conditions

The bearings are blackened or scored
The dowel holes in the bearings are eggshaped.
The connecting rods have been replaced
Important: Do not oil the backs of the bearings before installationOiling the
backs of the bearings cuts down clearance between the bearings and the
crank journals
4If the bearings are not obviously wornreinstall the caps on the connecting
rods and measure the bearings with a micrometerBe sure each cap is a mate
for the connecting rodOrient each cap SO that the cap code (a number and
letter)is On the same side as the code stamped in the connecting rodReplace
bearings that measure more than 5015 in(1274 cm)If the bearings are
for a reground crankshaft, subtract theoversizedimension [0040 or 0080
64
in(010 or 020 cm)] from 5015 in(1274 cm)
5Oil the pins and install them, aligning the notchesBe sure each crosshead
is a mate for the connecting rodBe sure the top (small) shoe and the code
stamped into the connecting rod are on the same side
6Drive two keys into each crosshead
7Secure the pins and keys with the dished washers, screws, and nuts
Ring Gear and GearSupport Bearing Maintenance

1. Check the ring gear for the following problems
teeth shaved down by a cracked worm gear
badly pitted teeth blackened by heat
oil filter chronically dogged by bronze chips
If any of these conditions exist and if the pump is expected to remain in active
servicereplace the gear set to avoid further damage to the power end
2If the gearsupport bearing has good clearancescheck it for other forms
of wearThe radial bearing, the inner racethe two thrust bearingsand the two
thrust races are all parts of the gear-support bearingReplace the entire gear-
support bearing if any of the rollers or races are badly spalledif any of the
cages are broken, or if any of the races are badly pitted
3 If the ring gear is faulty or the gear support bearing is bad, remove the 24
lugs (right-hand pumps only)
Important: Do not cut the heavy wire that ties the lugs together
4. Support the ring gear with the splined side up for right-hand pumps or with
the splined side down for left-hand pumpsHeat the gear until the radial
bearing fails outRotate the gear to aid in even heating
5Assemble the ring gear and the radial bearing of the gearsupport
bearingBoth parts must be dean and burr-free
Turn the ring gear so that the splined side is down on a right-hand pumpOn a
left-hand pumpturn the ring gear so that the splined side is up
Heat the gear in an oven to 200F(93.7) to expand itDrop the bearing into
the gearTurn the bearing 90m both directions to seat itAllow it to cool
before proceeding
6. Secure the bearing with the lugs(right-hand pumps only)Be sure the
screws and lugs are wired
65
Worm Gear and Assembly Maintenance
Worm Gear
Inspect the worm gearIf possibleuse magnetic particle inspection to check
for invisible cracksCheck for wear and corrosionReplace crackedworn
or corroded worm gearsIf the ring gear is being replaced, replace the worm
gear
Drive-End Bearing
1Check the clearance of the driveend bearingFit the bearing on the race
which is still on the worm gear
If a 0.010-in(0.03-cm) feeler gauge fits under at least three of the
rollersreplace the bearing
If the driveend bearing passed the clearance test, inspect it. If the
rollers or races are badly spalledreplace the bearing
2Inspect the drive-end bearing race(old worm gears)If the bearing or the oil
seal has damaged it, remove the raceHeat the race to expand it
If the worm gear is without a new race at this pointinstall a new raceHeat it
to 200F(933 )before installation
Thrust-End Bearing
1Check the clearance of the thrust-end bearingFit the bearing OD the race
which is still on the worm gear
If a 0010 m(003 cm) feeler gauge Can be positioned under
at least three rollers, replace the bearing
If the thrustend bearing passed the clearance testinspect itIf the
rollers or races are badly spalledreplace the bearing
2Inspect the thrust-end bearing raceIf it is pittedremove it by expanding it
with heat
3If the worm gear does not yet have a new raceinstall a new raceHeat it
to 200F(933)before installation
Thrust Bearing
Inspect the thrust bearingIf the rollers or races are badly spalledreplace the
entire thrust bearing
If the bushing is damagedreplace itAlways replace the key
Important: Never intermix inner or outer spacers between bearing setsThe

spacers are matched and must be used only as originally packagedspacers
from different sets are intermixed, the clearances will not be correct, which will
cause premature bearing failure
66
Assembly
Slide Assembly
1Install the slidesUse 516-in(079- cm) screws and nuts to temporarily
secure the top slides that have oil holesInstall slides the same way they came
outThe No1 slide is installed next to the ring gear
2Measure the standoff with a micrometer between the end of each slide and
the case
3Install enough shims to make each slide stick out 0004 to 0006 in(0010
to 0015 cm) beyond the caseIf using a spacer assembly between the power
end and the fluid endmake the slides stand out 0001 to 0003 in(00025
to 00076 cm)
4Install the crosshead aligning jack
5Install the four inboard slide-clampsbut do not tighten them completelyBe
sure the protrusions of the feet are pointing out and touching the braces
6Install the four outboard slide-dampsRun the long set-screws out equally so
that the clamps are centeredDo not tighten them completely
7Tighten the inboard slide-clamps
8Make sure the long set-screws of the outboard slide clamps are tight and
lock them with the short set-screws
9Remove the jack
10. Remove the screws and nuts that are supporting the top slides
11Wire the screws of the inboard slide clamps to the braces
12Install the baffle
13. Install the short crosshead cover and a new gasketUse a pipe sealant on
the screwsUse seal washers and flat washers
14. Install the long crosshead cover and a new gasketUse a pipe sealant on
the screws. Use seal washers and flat washers.
Crankshaft Assembly
1. Install the retainer ring in the caseThe ring break is positioned at the top
2Temporarily install the injector coverDo not use all the screws or the
gasketThe cover is temporarily installed to support the crankshaft during
installation
3. Install the weldingrod ring if requiredAll right-hand pumps and a few
left-hand pumps require a weldingrod ring
4Position the Crankshaft so that the splined end is up and install the flanged
Stud. Be sure to wire the screws
5Oil the main bearings and racesInstall the Crankshaft in the caseusing a
lifting eye and hoistSpinning the crankshaft during installation helps ease
67
RingGear Assembly
1 If the bearing support is newcalculate the number of shims to use under
the bearing support by using the ring-gear shimming calculation procedure and
steps a through h.
a. Measure the flange of the bearing support (Dimension A)
b. Measure the thickness of the gear (Dimension B) and divide by 2
c. Measure the lip of the of the radialgear bearing (Dimension C)
dMeasure the thrust-bearing race(Dimension D)
eMeasure the roller (Dimension E)
fAdd Dimensions A through E
gSubtract the total in Step ffrom the dimension stamped on the
case (Figure 46Page 4-20)
hDetermine the gear offset and add or subtract from the total in Step
gThe answer will indicate the number of shims to place under the
support
68
2Install the bearingsupport shimsIf the same bearing is reusedreuse the
same shims that were removed during disassemblyIf using a new bearing
support, install the number of shims you determined in Step 1
3Install the bearing support by using the lifting eyes and a hoistSecure the
support with the 16 short screws and washersTorque to the value in Table
4With the bevel downinstall the first thrust race of the gearsupport
bearing
5Oil the ID of the inner raceInstall the inner race of the gearsupport
bearingThe small hole in the race goes toward the fluid-end opening in the
caseThe race can be heated to 200.F (93.3C) to make installation easier
6Liberally oil the first bearing of the gearsupport bearingand install it
7Liberally oil the ringgear teeth and the bearing rollers in the gear and
install itSpinning the gear aids in installation
8Lubricate the second thrust bearing of the gear-support bearingand install
it
9With the bevel upinstall the second thrust race of the gearsupport
bearing
10Determine if the ring gear is running trueRotate the gear with a dial
indicator against itIf the indicator registers more than O003 int00076 cm)
remove the gear from the pump and the radial bearing of the gear-support
bearing from the gearDeburr the gear surface that contacts the side of the
bearing
11 Determine the number of shims required under the thrust ring by
measuring the standoff between the thrust race and the bearing supportThe
number of shims equals the standoff plus 0001 to 0004 inf00025 to
00101 cm)
12Install the correct number of shims
13Install the thrust ring, securing it with the 16 long screwsThe thrust ring
has two blank holesThis condition is normalTorque to the value in Table
14 Check the clearance in the thrust bearings of the gear support
bearingPut a dial indicator against the ring gearPry up on the gear while
watching the indicatorIf clearance is not 0001 to 0004 inthe thrust ring
might be overshimmedRepeat Steps 11 through 14 until the clearance is
correct
15Wire the heads of the thrust-ring screws
16Install the clampring adapter(right-hand pumps only)
17Install the spline-drive flangeSecure it with the 24 clamp washers and
screwsApply thread lubricant to the screw threads to make them easier to
installBe sure to get the welding rod through the washers and wire the screw
heads
69
TABLE 2.1-TPH400 FASTENER TORQUE VALUES
TOQUE ft/lb (N-M)
Fastener Type Thread Size Molybdenum-based Oil
Thread Lubricant
Fluid-End Attaching Stud 1-14NS 200(271) 400(542)
Fluid-End Attaching Nut 1-14NS 640(868) 1280(1735)
3
Fluid-End/Top-Tie Bolt 1 /8-12NF 1500(2034) -
3
Fluid-End/Bottom-Tie Bolt /4-16NF 200(271) 340(461)
Discharge-Flange Stud 1-14NS 200(271)
Discharge-Flange Nut 1-14NS 580(786)
Plunger Nose-Plug 1-14NS 200-300(271-407)
Plunger tie-bolt 1-14NS 300-400(407-542)
Pushrod retainer 1-14NS 400-500(542-678)
Pushrod Tie-Bolt 1-14NS 500-600(678-813)
3
Connecting-Rod cap Bolt /4-10NC 110(149)
1
Gear-Support Flange /2-13NC 50(68) 100(136)
1
Gear-Support Thrust Plate /2-13NC 60(81) 120(163)
70
Worm-Gear Assembly Maintenance
Holroyd-Drive Pump
1Oil the bearingInstall the drive-end retainer and bearing (without the inside
race)and a new gasket
2Install the retainer cover and a new gasketInstall a new seal in the cover
3Install the worm gearBe sure the locknut in place to protect the threads
Completing Installation
Installation of the thrust-end retainer, bearings, shimsand oil pump are
identical on Holroyd-and cone-drive systemsInstall the thrust-end retainer and
bearing as well as a new O-ringTap the retainer into position with an
aluminum, brassor nylon hammerBe careful not to mar the surface of the
retainer that contacts the oil pump
1Install the thrust-end bearing thrust race
2Install the bushing key in the worm gear
3Install the bearing bushing
4Install the locknut
5Install the screw in the locknut
6Install the bearing key in the bearing bushing
7With the bevel in first, install one of the thrust races for the thrust
bearing
8Install the inner spacer for the thrust bearing
9Oil one of the bearings of the thrust-bearing setInstall the bearing
10Install another thrust racewith the bevel in last
11Install a third thrust racewith the bevel in first
12Lubricate another bearing of the thrust bearing and install it
13Install the outer spacer of the thrust bearing
14With the bevel in last, install the last thrust race
15. Determine the number of shims under the oil pump
aUse a micrometer to measure the standoff between the last thrust
race of the thrust bearing and the surface of the thrust-end retainer that
contacts the oil pump
bUse a micrometer to measure the oil pump to determine the distance
between the surface that contacts the thrust-end retainer and the surface that
contacts the thrust bearing
CSubtract the measurement in Step 15b from the measurement in
Step 15aAdd 0009 in(0023 cm)
16 Install the correct number of shims to equal the final number
71
calculated in Step 15c
17Install the pump drive adapter
18Equip the 0n pump with a new O-ring and install the pumpSecure the
pump with nuts and screwsUse thread lubricant on the threads
19On a conedrive gear set, check the contact pattern of the ring and
worm gearsPaint the worm gear with Red Lead or a substituteoverlapping
slightly on the blue dye applied earlier
20Put a drag on the power end (the weight of a fluid end is sufficient) and
turn the worm gear untilthe ring gear has made at least four full turnsCheck
the contact patternIt begins within 3 inof the entering end of the worm-gear
thread and extends to within 8 inof the major relief on the trailing end
21Check the pattern on the conedrive ring gear to see if it resembles
the pattern in Figure48
22Check clearance in the thrust bearingPut a dial indicator on the end
of the worm gearMove the gear in and out with a pry bar to a clearance of
O008 to 0010 in(00203 to 00254 cm)If it does not meet this clearance
remove the oil pump and add or remove shims to correct the clearance
23Install the oil pump
24Install the suction hose On the oil pump and tighten the clamp
25Install the discharge hoseUse pipe sealant on the threads
26Install the two hoses on the bypassUse pipe sealant on the threads
27Install the spline-drive coupling
28Install O120 in(00305 cm)(right-hand pumps)or 0060 in(O1524
cm)(left-hand pumps)of crankshaft shims and the spider bushing This
measurement is temporaryYou may need to add or remove shims later to
position connecting rods in the Crossheads
29Install the spiderSecure it with the four screws and the nutInstall the
cotter key through the nut, and wire the heads of the screws
30Remove the injector cover
31Install the injector and a new gasketOrient the injector so that the port
aligns with the lube-line bracket
If using a pump manufactured before 1973secure the lock washer and
nut
If using a pump manufactured after 1973bolt the injector from the
outside
31Equip the injector driveshaft with a new O-ringInstall the injector
driveshaft into the crankshaft
32Install the injector Cover and a new gasketGuide the drive shaft into
the injectorPoint the port of the injector toward the lube-line bracketSecure
the cover with me 16 screws and lock washers
33Install the injector nippleUse pipe sealant on the threads
34Install the hose on the nippleUse pipe sealant on the threads
Crosshead and ConnectingRod Assembly Maintenance

72
1Install the crossheads in the power end in the same order they were
removedwith the No1 crosshead next to the ring gear
2Gauge the clearances between the top shoes and slides with a feeler
gaugeThe correct crosshead clearance is O006 to 0008 in(00152 to
00203 cm)If a bore is taperedthe clearance is established at the smallest
point in the bore
3If the clearances are incorrect, add or remove shims beneath the top shoes
to make them rightIf shims thicker than 0025 in(00635 cm) are required
shim both the top and bottom shoesReinstall the crossheads and make a final
check of the clearances
4 Oil the shoes slides crankshaft journals and connecting rod
bearingsInstall a crosshead and connecting rod with the No1 crosshead next
to the ring gearInstall the top(small)shoes in theuppositionThe stamped
code of the connecting rod is positioned upPosition the crankshaft journal
toward the fluidend opening and slightly down for easier installation
5Oil the bearings and install the rod capsMake sure the caps and connecting
rods are mates and that the cap code is upTorque the screws and wire the
heads
Repeat Steps 4 and 5 for each of the remaining crossheads and connecting
rods
6Look through the access holes in the back of the case and check clearances
between the sides of the connecting rods and crossheadsIf necessaryadd or
remove crankshaft positioning shims behind the spider to center the rods and
crossheads
7Install the gear cover and a new gasketUse fiat washers on all the
screwsUse pipe sealant and seal washers at the bottom where tapped holes
exist completely through the case
Pump Preparation
1Install the seal plate or platesReplace corroded platesespecially if the
wipergland seals have nothing to seat against
2Using a chain and hoist, install the fluid endTorque the 12 nuts(Table
Page 4211 by using the locknut wrench and the extensionPut thread
lubricant on the stud threads
3Install the tie bolts with the socket wrench and apply torque
4Position the plungers against the Crossheads by using the two inserting
tools.
5Use a nose wrench and one of the supports to install the plunger noses and
sealsMake sure the rubber parts of the seals have not been damagedLightly
oil the plunger faceseal, and noseand tighten the nose.
6Install the cylinder-head coversProperly position the spacer rings in the
boresBe sure the gaskets are in good condition and lubricatedLubricate
retainer threadsTighten the retainers by alternately striking all three lugs until
73
a solid ringing sound occursTightening the retainers usually requires10 to 15
strikes with an 8to 12-1b(363 to 544-kg)sledgehammer
Caution: Make sure the cylinder-head covers are tightA fatigue crack from
cyclic loading can occur if threads are not tightened enough
7Install the pump by securing the mounts and connecting the plunger
lubricator hosethe coolant hoses, and the driveshaft
8Fill the power end with oilUse the heaviest grade oil possibleMake sure
that the pour point of the oil is at least 10F( 122C) below the overnight
low temperature expected at the locationCheck the lubrication charts in
Section 2
9Check the setting of the bypass valve by running the pump and watching the
oil-pressure gaugeThrottle the engine to 1,500 revmin, put the transmission
in a midrange gear, and turn on the plunger lubricator
Caution: Do not run the pump more than 15 minutes unless fluids are being
circulated Lack of fluid lubrication may damage the pump valves and may
damage the bearing surfaceswhich will result in premature bearing failure
10On pumps with welded, steel-body bypass valves, adjust on pressure

by adding or removing shims(Part No31611958)behind the spring(Figure
49)On pumps with a cast aluminum bypassvalve body, use the adjustment
screw to regulate pressure
TPH400 Fluid End and Spacers

The fluid end is the second main assembly of the pumpThe fluid end uses
energy that has been modified by the power end to move water, cement,
fracturing fluidsand other liquids and materialsSeveral fluidend sizes are
available that allow a wide range of pressurevolume combinations
On most pump configurationsa spacer assembly is used between the fluid
end and the power endThe spacer helps prevent fluids in the fluid end from
getting into the cavity(sump)of the power end
Spacers are used on all new pumpsFracturing pumps use L- 2 spacersand
cement pumps use L-4 spacers
See Figure 12Pages 14 and 1-5for a schematic of an HT 400 pump with
right-hand power endan L4 cone drive spacerand a 6 influid endFigure
12 is referred to throughout this section with Locx identifying the location of
parts
Changing Fluid-End Assemblies

Fluid-end assemblies (figure 1 2 Loc 25)have two possible tie-bolt
74
configurationsThe first configuration has a top and bottom fie-bolt(Figure 12
Locs40 and 41)The second configuration has three top tie-bolts(Figure
523)
Disassembling the Top and Bottom Tie Bolts

The following instructions are used for disassembling the top and bottom
tie-bolt configuration
1Remove the fluid end by following the disassembly steps under Changing
Fluid End with SpacerorChanging Fluid End without Spacer
2Position the fluid end on the foot end and remove the bottom tie-bolt
Note: Spacers and seals are compressed if the top fie-bolt is removed first
3Remove the top tiebolt
4. Remove the four nuts from the discharge flangesRemove the flanges and
flange seals
5Separate the sectionsand remove the spacers and seals
Assembly
1Clean the seal bores of the sections not discarded and check them for fluid
cuttingIf the shoulder that backs up the fluid seal is eroded, replace that
fluid-end section
2Plug unused stud holes with grease to prevent rust
3Assemble the fluid-end sections with the spacers and new seals
4Install the discharge flangesUse new seals(Plugged flanges have two
seals and a spacer)
5Coat the threads of the top tie-bolt with thread lubricant, install the tie bolt,
and torque it
6Coat the threads of the bottom tie-bolt with thread lubricant, install it, and
torque it
7Install the fluid end using the assembly steps in the following section
Changing Fluid End with Spacer, or use the assembly steps in Changing
Fluid End without Spacer
Disassembly
1Disconnect the plunger-lubricator hose
2Use a sledgehammer to remove the cylinder-head covers.
75
3Remove the plunger noses and sealsUse a support with either of the nose
wrenchesTo prevent the push rods from turning, use a suitable tool
4Move the plungers into the fluid end by turning the powerend input shaft
with a pipe wrenchAttach a chain and hoist to the fluid endremove the 12
nutsand remove the fluid end
Assembly
1If a stud has been galled, remove it with a pipe wrenchCheck the threads
in the spacerRetap or drill, tapand helicoil damaged threadsAfter
applying thread lubricant to the threadsinstall a new stud with a stud
driverReplace nuts that have damaged threads
2If an L-spacer is usedchange the push-rod noses when changing from one
diameter of plunger to another
3Install or remove the seal plate as necessary
4Using the chain and hoist, fit the new fluid end on the spacerApply lubricant
to the threads of the studsCheck the parts list to see if washers are used
under the nutsInstall the 12 nuts(and washers if required)Use the locknut
wrench and the extension to torque the nuts
5If fluidend sizes are switched, check the parts list to be sure the correct tie
bolts are availableChange the tie-bolts if necessaryKeep the push-rod noses
from turning with the L-Spacer bar during removalLightly lubricate threads
with oil
6To center the wipersloosen the screws securing the glandsPosition the
glands and retighten the screws
7Lubricate the plungers and position them against the push-rod noses by
using the two inserting tools
8Lightly on the plunger face, seal, and noseInstall the plunger noses and
seals by using a nose wrench and support that are the same diameter as the
plunger boresHandtighten the noses so that the plungers can be centered
9To secure the pressure packing, run the nuts out of the wiper glandsWith
the packing wrench, tighten the nuts as tightly as possible To prevent
overtightening, do not use an extension on the wrench
Caution: Run the pump for about 15 seconds to center the plungers in
the packing
10Torque the plunger nosesUse a nose wrench and a supportDo not over
tighten the noses
1 1Install the cylinder-head covers with a sledgehammerMake sure the steel
spacer rings are in place and that the rubber gaskets are in good
conditionLubricate gaskets and the threads on the retainerContinue to
hammer retainers by alternately striking all three lugs until a solid ringing
sound occurs Generally,10 to 15 strikes with an 8-to 12-1b(3 63-to
76
544-kg)sledgehammer are required
Caution: Make sure the cylinder-head covers are tightA fatigue crack from
cyclic loading can occur if threads are not tightened enough
12Connect the hose for the plunger lubricator

13If the installed fluidend pressure packing is newbreak in the packing by
using clean waterIn 2,000 psi(13790 MPa)incrementsbuild to twothirds
maximum pressure while tightening packingMaintain pressure for 20 to 30
minutesIf the fluid-end size is changedconvert the volume counter or the rate
and total volume indicator
Discharge Flanges
Procedures
1Remove the nut from the top tie-bolt
Note: If the fluid end does not have a bottom tie-bolt, it has been outfitted with
three top tie-bolts
2Remove the two nuts securing the bottom of the discharge flange
3Use the nut driver to remove the bottom internal wrenching nuts on straight
flanges that are inset
4Remove the flange and the seal in a straight flangeRemove two seals and
the spacer in a plugged flange
5Clean the seal boreCheck the bore for fluid cuttingIf the shoulder that
backs up the seal has been erodedreplace the fluidend section by using the
procedure in Changing FluidEnd Sections,.
6. Install a new seal(two seals and the spacer on plugged
flanges)Reassemble the flangethe fluid end has three top tie-bolts,
see Three Top TieBolts
7Coat the threads of the studs with thread lubricant and install the two nuts
on the studsTorque the nuts with a calibrated torque wrench
8Coat the thread of the top tie-bolt with thread lubricant, and install the nut
on the top tie-boltTorque the nut
Important: Use a box-end wrench as a backupDo not use a pipe wrench as a

backupA pipe wrench will damage the surface of the bolt and may cause a
stress fissurewhich could crack
ValvesSeatsand Retainers
Disassembly
77
Valve
1Remove the valve covers and the cylinderhead covers
2Remove the discharge valves and springs
3Remove the suction-valve stops by using the tee wrench and the
adapter(The adapter is not used on singleguided valves)Pry
up on the lock spring with a screw driverand turn the stop 90 in
either direction
4Remove the suction valves and springs
Retainers and Seats

These steps are repeated for each of the discharge-valve seats
1If the valve seatsbushing retainersor bushings are worninstall the
spreader of the seat puller into one of the discharge valve retainers(No4 and
No5 valves only)
2Remove the lug retainer from the seat pullerInsert the seat puller over the
spreader and into the seatMake certain the lugs are under the seat properly,
and replace the lug retainer
3Use a hydraulic ram to install the top guide from the same size of seat in-
setter on the seat-puller shaftInstall the ram, nut, and safety guardRemove
the seat with the pump
If a hydraulic ram is not availablereplace the lug retainer on the seat puller,
and install the top guide from the same size of seat inserter on the seat-puller
shaftInstall the spacer sleevethrust bearing, and nutRemove the seat by
turning the nut with a pipe wrench
Repeat Steps 1 through 3 for the other two discharge-valve seats
If the fluid end has tapered valve seatssee Step 6
4Install the spring-loaded nose of the seal remover in a discharge-valve
retainerLock the remover onto the retainer by depressing the spring and
turning the t001
5Knock the retainer and the adapter(or seal)loose by using the weighted
handle of the seal remover as an impact hammer
Repeat Steps 4 and 5 for the remaining discharge-valve seats
6Remove the suction-valve seats by repeating Steps 1 through 3
7Follow Steps 4 and 5 to remove the suction-valve retainers and adapters(or
seals)(Tapered valve-seat fluid ends do not have suction-valve retainers and
adapters)
Assembly
Retainers and Seats
78
1Fit the bushing retainers into the three bores for the suctionvalve seats
Retainers are installed with the guide bushing facing towards the valve
Older retainers must be installed with the larger chamfer downOlder retainers
are marked THIS SIDE UP to make positioning easier
Newer retainers can be installed with either side up
2Use a seat installer to install adapters(frac valves)in the seat bores(In new,
tapered-bore fluid endsadapters are not used)Adapters and bores must be
clean and free of lubricant, and the O-ring must be placed correctly
3Using the seat inserter, drive the seats into the adapters or bores and
position the new O-rings
Caution: The inserter rebounds when the seat bottoms out
If the seat does not bottom out when driven into an adaptercheck to see if the
adapter is cocked and under the seatFluid-end seats with a tapered bore are
difficult to bottom outTo install the valve seats in a taper-borefluid end
pressurize the TPH400 pump to the appropriate pressures before going on
location
Note: Improper installation of valve seats can result in seats being pumped out
or result in the fluid-end bores being fluidcut
Repeat Steps 1 through 3 for the remaining suction-valve seats

4 Fit the remaining retainers into the bores for the discharge-valve
seatsOrient older retainers as described in Step 1
5Install adapters(frac valves)with new O-rings in position by using a seat
inserterDrive the seatswith new O-rings in positioninto the adapters or
bores by using the seat inserter
Valves
1Install the suction valvesspringsand stopsTurn the valve stops into the
bores by using the tee wrenchAn adapter is used on the end of the wrench
for all but single-guided valves
Be absolutely sure the lock springs of the valve stops are well seated in the
short, vertical grooves
Caution: The lock springs must be seated properly to keep the stops
from working out of the bores and into the path of the moving plungers
2Install the discharge valvesspringsand coversLubricate the cover

gaskets and the threads on the cover retainer
Be sure the gaskets are in position on the covers and the spacer rings are in
position in the bores
79
3Install the cylinder-head coversGaskets must be in good condition and
lubricatedSpacer rings must be installed in the bores of the fluidend
sectionsLubricate the threads on the retainerContinue to hammer the
retainers by alternately striking all three lugs until a sound OccursGenerally
10 to 15 strikes with an 8-to 12-Ib(363-to 544-kg)sledgehammer are
required
Caution: Make sure the cylinder-head covers are tightA fatigue crack
from cyclic loading can occur if threads are not tightened enough
4After installing the frac-valve seatspressurize the fluid end to onethird the
maximum working pressurePressurizing the fluid end
drives the seats into their adaptersminimizing chances of a seat being
pumped out during a jobHigher pressure may be required for seats installed
in fluid ends with a tapered bore
Caution: Do not exceed the maximum pressure limit of the fluid end
Pressure Packing and Plungers with Spacer

Disassembly
3 38-inFluid End
1Remove the cylinder-head covers
2 Remove the plunger noses and seals by using one of the two
nose wrenches and a supportIf a support is not availableuse
the handle of the socket wrenchUse a spacer bar to keep the
pushrod noses from turning
3Back off the nuts of the wiper glands with the packing wrench
4If an M 1 or D spacer is usedturn the powerend input shaft
until the tiebolt is withdrawn as far as possible from one of the
plungersScrew the plunger remover into the plungershort end
firstTurn the input shaft so that the tie-bolt pushes on the end of
the remover and partially extracts the plungers from the
packing
5Turn the power-end input shaft until the fie-bolt is withdrawn from the
plungerTake out the plunger removerReinstall it, this time with
the long end firstTurn the input shaft until the plunger has been
extracted completelyRepeat Steps 4 and 5 for the other two
plungers.
6Remove the plunger fie-bolts by using the socket wrench and a
supportUse a packing bar or other tool to keep the push-rod nose
from turning
7Remove the wiper glands
8Use a piece of wood to knock out the pressure packing, the
80
adaptersand the lantern ring from each packing bore
9Remove the check valves
4-in Fluid Ends

1Remove the cylinder-head covers
2Remove the plunger noses and sealsUse one of the nose wrenches
and a supportIf the support is not availableuse the handle of the
socket wrench normally used to remove plunger tie-boltsUse a
spacer wrench to keep the push-rod nose from turning
3 After installing a spacer bar to keep the push-rod nose from turning
remove the plunger tie-bolts by using the socket wrench and a
support
4Back off the nuts of the wiper glands with the packing wrench.
5Turn the power~nd input shaft until one of the push rods is withdrawn
into the power end as far as possibleInsert the plunger remover into
the plunger, Position the remover so that the short lobe is between the
end of the plunger and the push-rod noseTurn the input shaft so that
action of the push rod partially extracts the plunger
6Repeat Steps 1 through 5 for the other two plungers.
7Remove the three wiper glands
8Use a piece of wood to knock out the pressure packingthe adapters
and the lantern ring from each of the three packing bores
9Remove the check valves
Assembly
1. Clean the packing bores thoroughly Make sure no cement or other
material is stuck to the bores or the shoulders that the male adapters press
against
Check the packing bores for wearUsing a micrometer, measure each bore
at the point indicated by AGreatest wear Occurs at Point A where the
highly pressurized first and second packing rings rub
81
Packing Bore Dimentions
Fluid End in.(cm) DimentionA in.(cm)

3 3/8(8.573) 4.375/4.381(11.113/11.128)
4 (10.160) 5.000/5.006(12.700/12.715)
4 1/2 (11.430) 5.500/5.506(13.970/13.985)
Rreplace fluid end sections with bores that are worn more than 0.01
in. oversized.
2. Check the threads of the fluid end sections for cracks. These are the
threads that the cylinders heads screw into.
3. Use the packing-inserting tool to install a male adapter,
4Install the wiper glandsDo not install packing in themExtend the nuts
of the glandsbut do not tighten them
5Check alignment of the lantern rings to enstlre adequate flow of
lubrication to the packingLook through the lubrication holes to be sure
undercuts of the lantern rings are visible
6Install the tie bolts by using the socket wrench and a suitable support
Lighlly oil the threads and tighten the tie bolts
7Check the plungers for scratchesCheck for wear by comparing the
minimum wear areaReplace scratched plungers and plungers with the OD
worn more than 0005 in(0013 cm)
8Position the plungers against the push-rod noses by using the two
inserting toolsLubricate the plungers before inserting them
9Lightly oil the plunger facesealand noseInstall the plunger noses
and seals by using a nose wrench and a support that is the same
82
diameter as the plunger boresHandtighten the noses so that the
plungers cart be centered
10.To tighten the pressure packingrun out the wipergland nutsWith the
packing wrenchtighten the nuts as tightly as possible without using an
extension on the wrench .
torque the plunger noses see the toque table ,do not over tighten it.
Important Run the pump for about 15 seconds t0 center the plungers in
the packingFailing to do SO may CtlUSe premature failure
ofthe pushrod wiper seals or the packing.
11. Loosen the screws securing the wiper glands of the spacer. Center the
glands and retighten the screws.
12. Clean the check valves. Take them apart if necessary. Make sure
there is a positive seal in the reverse direction. Replace valves that do
not seal. Clean oil lineswith compressed air and clean exposed
connections.
13. reinstall the check valves with the arrows pointing toward the
ground.Install the lubrication supply hose. Use a pipe sealant on the
threads.
14 Break in the packing by using clean water. In 2000 psi(13.790Mpa) in
crements, build to two-third the maximum operation pressure while
tightenting the packing nuts and maintain pressure for 20 to 30
minutes. Break-in pressure should not exceed the maximum
expected working pressure
Changing packing, plungers, and Push Rods with L-spacers.

Replacing Wiper Seals in L-spacers
1. Remove the plungers and pressure packing
2. Knock the adapters off the three retainers.
3Remove the three wiper glands of the spacer
4Install a new seal in the wiper glandsInstall new Orings on the backs of
the glandsif necessary
5Attach the wiper tool to one of the adaptersPress the wiper gland over the
tool and onto the push rod by turning the powerend input shaftRepeat
this operation for the two remaining glands
6Install the plungers and pressure packing.
Replacing Wiper Seals and Push Rods in L-2 and L-4 Spacers
1Remove the plungers and pressure packing.
2Remove the three adapters.
3Remove the three retainers and O-ringsUse the socket wrench and
support
83
4Screw the plunger remover into the push rodsshort end firstTurn the
power-end input shaft so that the push-rod tie-bolt pushes on the end of the
remover and extracts the push rod from the wiper packingRepeat this
operation for the two remaining push rods
5Remove the wiper glands from the spacer,turning the power-end input shaft
to get the tie-bolts out of the way
6If the seals in the wiper glands&re worninstall new sealsReplace the
O-rings ifthey are worn
7Install the wiper glandsDo not tighten the screws at this time
8 Lubricate the threads of the retainerInstall unscratched push rodsSecure
he push rods with the retainersO-rings on the retainers should be in good
condition Use the socket wrench and a support to install the
retainersUsing the appropriate torque values shown intorque the
retainers
9Install the plungers and pressure packing
To Install the Packing
1Remove the plungers and packingdepending on the spacer style or

plunger size of the TPH400 pump
2Clean the packing bores thoroughlyMake sure that no cement or other
material is stuck to the bores or to the shoulders that the brass adapter
rings press against
Measure the packing bore ID for wearUsing a micrometermeasure
each bore at Point A.
84
3The seal carrier can be used many times because it does not wear
against the plunger like conventional packing brass
If a carrier is reusedremove any burrs or nicks with a file or emery
clothMake certain all the lubricating oil ports and seal grooves are
clean and free of cement or other pumping materialDiscard and
replace carriers that are severely corroded or damaged
Inspect the vee groove for fatigue cracks that may occur with long-term
service
4Lighny oil the outside of the carrierInstall an O-ring in the groove on
the OD of the carrierDo not roll the ring as it slides over the outside of
the carrierSnap a lubricant seal into the groove in the IDThe lube
seal is installed with the lip toward thefluid end
5Check the brass adapter ring to make sure it is not bentRemove any
burrs or cementLike the carrier,the brass adapter ring can be reused
several times Replace it only if the ring is warped
6Install the homogeneous rubber header ring with the flat side toward the
brass adapter
7lightly oil the vee ring packing and install it with the open end of the vee
toward the header ringPull it into place by using the packing-inserting
tool
8Inspect the brass backup ring for wear or damageThese rings usually
last two or three repackingsBurrs or small nicks Can be removed with
emery cloth
9Install the carriertaldng care not to cut the O-ring
10Continue with the assembly of the fluid end
Caution : Do not overtighten the packing nutHeader rings are extremely

sensitive to overtighteningIf the header ring is overtghtenedit can
either burn up or tear up
While the accepted standard is that proper pre-load is about equal to a 30-1b
puU on the standard short-packing wrenchit might be be~er to measure th(
amount of compressionThis adjustment should be done using a standard
packing break-in procedure at the service center,not on the the job
Periodic adjustment may be required(at approximately five-job intervals)
because the rubber header ring may relax with time
85

A08012200E D en TPH400

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What are the main parts of the 400 pump?

What are the main parts of the 400 pump?

What does the power end do?

What does the power end do?

Service Manual

Table 1.2Power End

Table 1.3Pump Assembly Weight

Table 1.5Fluid-End Weight

Table 1 .6Discharge Pressure

Operation Limits (8.6:1 gear)

Chemicals Resistance Chemicals Resistance

4. Turn off the prime mover (engine or electric motor).

6. File down or replace parts that have sharp or jagged edges.

7. Use a remote-operated choke to build pressure in a positive-displacement

Warning: Never use a full-closing valve to build pressure in a positive

11. Never weld on a pressure-containing part (such as a fluid end, discharge

Warning: Failure to follow all precautions could result in serious or fatal

Warning: Do not operate H2S by TPH400 pump. Please contact with

Maintenance During theJob

Maintenance After the Job

1. As lubricant working temperature >67, you should more frequently check

3. Lubrication function will reduce if you mix artificially synthesized lubrication

4. Recommend use extreme-pressure additive which has not contain sulfur

Lube Selector by outside

Tighten packing max pressure

400 overload restriction

Operation restriction (8.6:1)

Discontinue: continue working less than 4 hours.

Interval: continue working between 4 hours and 8 hours

Continue: continue working more than 8 hours

Youd better make a periodic repair plan which could

prevent equipment from working abnormally cause by

temperature for spring and autumn separately

Power-end repair should adopt specialized tools (some unlisted

(Common tools list above and SJS accept customizing)

Tools also require:

Some parts require large ovens heating when reassembly.

High class instrument (include callipersmicrometeraltimeterbore dial

Multi-size wrench and torque wrench.

Wire pump bracket.

Removing the Connecting Rods and Crossheads

Removing the Worm Gear

P40-14-300 GEAR,WORM 8.6:1(HOLROYD)SUBASSEMBLY

|---P40-14-101 0001 SCREW,HEX SOCKER,3/8"-16NCx1 1/4",UNBRAKO/LOC-WEL

|---V06-68-473 0002 WASHER,FLAT,3/8" SAE,STEEL

|---P40-14-103 0003 COVER,OIL SEAL RETAINER

|---P40-14-104 0004 SEAL,OIL,53-IN. x 7448,FL,4"B x5 1/2"ODx1/2"WIDE

|---P40-14-105 0005 BEARING,DRIVE END-WORM SHAFT

|---P40-14-106 0006 GASKET,WORM HOUSING INPUT END

|---P40-14-107 0007 RETAINER,BEARING,WORM-DRIVE END

|---P40-14-308 0008 GEAR,WORM,SUB-ASSY,8.6:1 (HOLROYD),POWER-END ASSY

|---P40-14-109 0009 KEY,WORM-THRUST BEARING SPACER

|---P40-14-310 0010 ADAPTER-BROWN. SHARP LUBRICATOR PUMP

|---000P569267 0011 O-RING,NITRILE 90 DURO #267,PEROXIDE CURED

|---P40-14-115 0012 RETAINER,IRON WORM-THRUST END BEARING

|---P40-14-116 0013 BEARING,THRUST-END,WORM SHAFT

|---P40-14-117 0014 KEY,WORM-THRUST BEARING

|---P40-14-118 0015 BUSHING,WORM THRUST BEARING