WET/TWS600S PLUNGER PUMP

USER’S MANUAL

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 PREFACE

This instruction is a guidance to the operation and maintenance of WET/TWS600S plunger

pump and shall be read carefully before operating this equipment. This book includes technical
specification, structures, operation, daily maintenance and trouble shooting. This instruction
manual does not include the contents of how to use and maintain diesel engine and hydraulic
mechanical transmission box. Please refer to related technical documents that are supplied along
with the equipment.

For any questions, please contact：

Fax ： +49 3902-939 46-20

Email： inf@act-ws.de

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 Table of Contents
Chapter 1 WET/TWS600S Pump Description

Chapter 2 WET/TWS600S Pump Performance Parameters

Chapter 3 Structure Description

Chapter 4 Shipping and Storage

Chapter 5 Pump Installation Highlights

Chapter 6 Lube System Requirements

Chapter 7 Pressurizing System Requirements

Chapter 8 Pump Operation and Maintenance

Chapter 9 Consumable Parts List

Chapter 10 Accessories and Tools

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Chapter 1 WET/TWS600S Pump Description

The WET/TWS600S pump is a reciprocating, positive displacement, horizontal

single-acting, triplex plunger pump which is rated at 600 Brake Horsepower input maximum. The
WET/TWS600S pump is designed for intermittent duty well service applications such as
acidizing, cementing, fracturing, well killing, gravel packing, etc.

The WET/TWS600S pump consists of a Power End, Speed Reducer Assembly and a Fluid
End Assembly. The Speed Reducer can be installed on either the right hand or left hand side of the
pump and can be installed in any one of 17 different input shaft locations to accommodate a
number of different pumping unit drive configurations. Different fluid cylinders are available to
accommodate several plunger sizes for a variety of pressures and volumes.

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

The basic design and structure features of WET/TWS600S plunger pump is as following:

A．Power End Design

Part description Structural features

Housing High strength steel welded/ stress relieved, line bored. Geometric Tolerance
measured by CMM.
Crankshaft Machined from one-piece heat treated alloy steel forging. Precision grind
crank journals. Supported by four heavy-duty cylindrical main roller bearings.
Connecting rods Precision machined from high strength forged steel.
Crossheads Precision machined from high strength ductile iron casting.
Crosshead slide Precision machined from high strength alloy cast iron with semi-cylindrical
design.
Wrist pins Precision machined from heat treated alloy steel.

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B．Speed Reducer Design

Housing Fabricated steel/stress relieved, line bored. Parallel shaft type design.
Bull gear Precision machined from high strength alloy steel casting. Induction hardened
gear teeth. Supported by two heavy duty tapered roller bearings.
Pinion gear Induction hardened gear teeth. Supported by two heavy duty tapered roller
/input shaft bearings.

C．Fluid End Design

Cylinder block ―Valve over Valve‖ Integrated design. Precision machined from high strength
alloy steel forging. Undergo pressure test of 1.5 times pressure.
Plunger Machined from steel w/precision ground hard overlay tungsten-base alloy with
hardness≥HRC65
Plunger ―Self-adjusting‖ type packing assemblies. Precision molded fiber reinforced
packing V-type pressure rings. Supported by precision machined bronze adapter rings.
Various compositions available for all common well service fluid media such as
hydrochloric acid, cement, fracturing sand slurries, hydrocarbons, toluene, etc.
and a wide range of ambient temperatures and fluid temperatures.
Valve Wing guided well service type valves w/replaceable urethane or neoprene
assemblies inserts. Tapered well service type valve seats w/auxiliary seal ring.
Valve springs Long lasting coil springs engineered for a wide range of well service
applications. Designed for spring rates, installed spring loads, and valve
cracking pressures unique to well service pumps.
Suction valve Low fluid restriction type keepers located out of the high stress plane of the
keepers fluid cylinder.
Discharges Optional
flanges
Suction Optional
manifolds

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 Chapter 2 WET/TWS600S Pump Performance Parameters

1. WET/TWS600S Pump Performance Parameters

Max. Brake Power………………………………………..600BHP（447Kw）

Max. Load ………………………………………………100,000 Lbs(43,360kg)
Stroke Length…………………………………………….6″(152.4mm)
Transmission Ratio………………………………………..4.6:1
Overall Dimension（LxWxH）……….. … ……………73.38″×50.96″× 29.37″
(1864×1292×746mm)
Net weight（About）…………………………………….5,400 Lbs（2449kg）

Performance Parameters *
Plunger OUTPUT DISPLACEMENT AT PUMP STROKES PER MINUTE/PINION RPM

Dia PER REV 50/230 120/552 200/920 300/1380 450/2070

Inch Gal/rev GMP PSI GMP PSI GMP PSI GMP PSI GMP PSI
2 2 2 2
(㎜) (liter/rev) (L/M) (Kg/㎝ ) (L/M) (Kg/㎝ ) (L/M) (Kg/㎝ ) (L/M) (Kg/㎝ ) (L/M) (Kg/㎝ 2)

2 1/2‖ .38 19 20,372 46 20,165 76 12,099 115 8,066 172 5,377

(63.5) (1.4) (72) (1436) (174) (1421) (290) (835) (434) (568) (651) (379)

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

(69.9) (1.8) (87) (1186) (210) (1174) (350) (705) (526) (470) (788) (313)

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

(76.2) (2.1) (104) (997) (250) (987) (417) (592) (625) (395) (938) (263)

3 1/2‖ .75 37 10,394 90 10,288 150 6,173 225 4,115 337 2,744

(88.9) (2.8) (142) (732) (341) (725) (568) (435) (851) (290) (1277) (193)

4‖ .98 49 7,958 118 7,877 196 4,726 294 3,151 441 2,100

(101.6) (3.7) (185) (561) (445) (555) (741) (333) (1112) (222) (1668) (148)

4 1/2‖ 1.24 62 6,288 149 6,224 248 3,734 372 2,489 558 1,660

(114.3) (4.7) (235) (443) (563) (439) (938) (263) (1407) (175) (2111) (117)

INPUT POWER(Kw) 253(188) 600(448) 600(448) 600(448) 600(448)

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Based on 90% ME and 100 %VE- Intermittent Service Only.

2. The rotating direction of crank（subject to fluid end and lube oil tube）

TWS-600 is a kind of single acting pump. Make sure the crankshaft rotates at the lower limit of
maximum connection rod angle. The rotating direction of crankshaft is always from lubrication oil
tube to rear pump (See above Fig).

3: There are following changes of 600 pump installation position and direction:

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A. Set reducer box left

Two kinds of speed reducers can choose 16 installation types. See the above drawings.

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B. Set reducer box right

Two kinds of speed reducers can choose 16 installation types. See the above drawings.

3. WET/TWS600Splunger pump operation curve

4. WET/TWS600S Tach Drive//Rate Meter Calibration Specification

Plunger * FLUID DISPLACEMENT

Diameter PER TACH DRIVE REVOLUTION PER TACH DRIVE REVOLUTION
Inches @ 95% V.E. @ 100% V.E.
(㎜) GPR BPR LPR GPR BPR LPR

2 1/2‖
.0726 .00177 .2747 .0764 .00187 .2892
(63.5)
2 3/4‖
.0879 .00209 .3328 .0926 .00220 .3504
(69.9)
3‖
.1047 .00249 .3961 .1102 .00262 .4170
(76.2)
3 1/2‖
.1424 .00339 .5391 .1499 .00357 .5675
(88.9)

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 4‖
.1860 .00443 .7042 .1958 .00466 .7413
(101.6)
4 1/2‖
.2355 .00561 .8912 .2479 .00590 .9382
(114.3)
Note: the volumetric efficiency and resulting displacement will vary slightly due to operational
factors such as pump speed, supercharge conditions, and the specific gravity of the fluid
being pumped.

V.E. = Volumetric efficiency of pump

GPR = U.S. gallons per revolution
BPR = U.S. barrels per revolution
LPR = Liter per revolution

5. Conversion Factors

Multiplicand Multiplier Result

Barrel（America） 42 Gallon（America）

Gallon（America） .023809 Barrel（America）

Gallon（America） 231 cubic inch

cubic inch .004329 Gallon（America）

Cubic foot/second 448.831 Gallon/minute

Gallon/minute .002228 Cubic foot/second
Foot (water column) .4331 lbs/ square inch
PSI 2.309 Foot (water column)
KW 1.341 HP
HP .7457 KW

Chapter 3 Structure Description

Pump Assy

WET/TWS600S Pump consists of a Power End 1, Speed Reducer Assembly 2 and a Fluid End
Assembly 3.

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Power End Assembly

Item No. Drawing No. Description Qty Material Remarks

1 B600-01000092 Top Cover 1 ZL111

2 B600-01010000 Crankcase Assy 1 Assembly
3 B600-01020003 Supporting Leg 2 Assembly
4 B600-01060000 Conn Rod/Crosshead Assy 1 Assembly
5 B600-01070003 Clamp Assy 3 Assembly

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 6 B600-01080001 Crankshaft Assy 1 Assembly

Speed Reducer Assembly

Item No. Drawing No. Description Qty Material Remarks

1 B600-03000052 Bull Gear 1 42CrMo

2 B600-03000122 Flange,Rectangular Spline 1 40Cr Optional

3
B600-03000134 Spline Shaft Baffle 1 Q235
4 B600-03000144 Spacer 1 35

5 Pinion Gear（rectangular spline）

B600-03000152 1 42CrMo Optional

6 B600-03010003 Small Bearing Assy 2 Assembly Oursourcing

Welded
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B600-03020000 Housing Assy 1 Assembly
8 B600-03030002 Big Bearing Assy 2 Assembly Oursourcing
9 GB9877.3-88 Sealing Ring 1 Oursourcing

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Fluid End Assembly

Item No. Drawing No. Description Qty Material Remarks

1 B600-02000044 Suction Spring 3 ●φ6/60Si2MnA

2 B600-02000051 Cylinder 1 30CrNi2MoV
B600-02000062 3 1/2‖
3 B600-42000022 Plunger 3 20Mn 4‖
B600-52000022 5‖
4 B600-02000073 Suction Valve Stop 3 ZG310-570
5 B600-02000083 Valve Seat 6 20CrMnTi
6 B600-02000094 O Sealing Ring 3 N552
7 B600-02000104 Discharge Spring 3 ●φ7/65Mn
8 B600-02000112 Threaded Retainer 5 42CrMo
B600-02000124 Small Rod
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B600-02000134 Large Rod 4 each 42CrMo
10 B600-02010003 Measurement Adapter Assy 1 Assembly Optional
11 B600-02030001 Suction Manifold 1 Assembly
12 B600-02040004 Discharge Cover Assy 3 Assembly
B600-02050003 3 1/2‖
13 B600-42020003 Sealing Assembly 3 4‖
B600-52020003 Assembly 5‖

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 14 B600-02060004 Valve Assy 6 Assembly
15 B600-02070004 Suction Cover Assy 3 Assembly

Chapter 4 Shipping and Storage

1. All the pumps should be shipped under dry condition, and must be flushed and filled with the
proper lubricant before operation. Pumps may be flushed with diesel or light oil. When
pumps are shipped by ocean cargo, care should be taken to create the pump in a watertight
container and ship below deck to prevent salt water contamination.

2. New pumps are not prepared for long periods of storage and should be put in service as soon
as possible. To prepare a pump for storage after prior use, clean the fluid end and flush it with
good rust preventive. Plug all fluid end discharge and suction openings. Drain oil from power
end, thoroughly clean and flush with good rust preventive which will not clog oil passage.
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.

3. Pumps which 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 rubber plunger packing and valve inserts will stick to the matching metal parts
and become damaged upon startup if not disassembled and lubricated first.

Chapter 5 Pump Installation Highlights

The proper installation of yourWET/TWS600Spump is a must in obtaining long life and trouble
free service. Particular attention must be given to the following item:

A. Power Source
The prime mover (usually a 2100 RPM diesel engine) should not be rated at more than 725
BHP (intermittent services) in order to avoid overpowering the pump

B. Power drive chain

The drive chain which connects the pump to the engine should include a transmission (5

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 speed or more) and mechanical driveline with universal joints and a slip joint in order to fully
utilize the pump’s wide range of pressure and flow capabilities.

A power shift type transmission with integral torque converter and automatic lock-up clutch
will provide the most trouble-free means of shifting under pressure. When using an ordinary
mechanical transmission with manual clutch, extreme caution must be exercised when
clutching and shifting in order to avoid introducing severe shock loads to the pump’s input
shaft. When using any transmission with a ―high gear‖ or ―overdrive‖ ratio greater than 1.0:1,
the ―overdrive‖ gear range must be blocked out in order to avoid over-speeding the pump.
When using a transmission with a torque converter and/or a low gear ratio of 5.0:1 or lower,
extreme caution should be exercised to avoid over-pressuring the pump when operating in
low gear or converter mode.

The mechanical driveline should have a ―Diesel Engine Use‖ torque rating of approximate
1250 to 1700 ft. lbs. (6500 to 8900 ft. lbs. Short duration) and should have no less than 1‖
slip capacity. The manufacturer’s recommendations for maximum installed angle, maximum
RPM, etc. must not be exceeded.

C. Power End Installation:

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

D. Power End Lubrication

WET/TWS600S well service plunger pump are shipped dry, do not include an integral oil
pump, and are designed for a pressure lubricated dry sump system. An auxiliary oil reservoir
and engine driven oil pump must be provided for proper lubrication. More information
pertaining to the power end lube system and power end lube oils is included in this manual.

E. Plunger Lubrication
WET/TWS600S well service plunger pumps require a force fed oil plunger lube system.
More information pertaining to the plunger lube system and plunger lube oils is included in
this manual.

F. Supercharging System

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 WET/TWS600S well service plunger pump require the use of a centrifugal slurry pump
supercharging system. More information pertaining to the supercharging requirements is
included in this manual.

Chapter 6 Power End Lube System Requirements

Providing a well designed trouble-free power end lube system is one of the most important factors
in obtaining maximum service and long life from the WET/TWS600S well service plunger pump.
Due to the nature of well servicing operations, the highest pump pressures and highest load
conditions occur at very slow pump speeds. This characteristic of well service pump operation
necessitates the use of an engine driven lube pump which will deliver maximum lube oil volume
at high engine speeds regardless of slow pump speeds. As a result of this operating characteristic
and the many different equipment design possibilities, it is not feasible for WET/TWS600S to
provide a power end lube system with the pump. The equipment manufacturer who builds the
powered well service unit must provide power end lube system components which are compatible
with the specific engine, transmission, etc. being utilized on the unit.

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

1. Oil reservoir:
A. Must be of 50 gallon minimum capacity.
B. Suction outlet to be 1 1/2‖ minimum and located as deep as possible.
C. Suction outlet and return inlets to be as far apart as possible.
D. Return fitting for drain back to be 3‖ minimum; return fitting for relief valve line to be
1‖ minimum.
E. A serviceable magnet located near the 3‖ return port is highly recommended.
F. Breather/filler cap to be 40 micron/25 CFM minimum and should include a built-in
strainer to prevent trash from entering the reservoir.
G. Dipstick or sight glass to indicate oil level in the reservoir.
H. Reservoir must be located below the lowest drain port in the plunger pump and as near
the plunger pump as possible (preferably directly underneath).

2. Lube system suction piping:

A. Must be 1 1/2‖ I.D. minimum throughout so that the suction flow velocity never exceeds

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 2 to 3 ft. per second.
B. Must include a suction strainer w/1 1/2‖ minimum port size, 40 to 100 mesh (400-150
micron) wire cloth, 300 sq. in minimum element area, 3 to 5 PSI (6 to 10 Hg) built-in
bypass, and rated at 50 GPM minimum flow. An in-line canister type strainer is much
preferred due to the ease of routine maintenance is cleaning the element.
C. A 1 1/2‖ minimum swing type check valve may be used in the suction line if the lube
pump is located above the fluid level in the reservoir.
D. The suction line should be as short as possible, should be free from excessive bends, and
should be wire reinforced to prevent collapsing. If longer than 10 ft. the resulting
friction losses should be compensated for by increasing the line size to 2‖ I.D.
minimum.

3. Lube pump:
A. Must be a gear type pump rated at 25 GPM minimum at its installed maximum RPM.
Inlet and outlet ports should be as large as possible w/1 1/2‖ inlet and 3/4‖ outlet
preferred.
Note: If the gear pump suction inlet port is smaller than 1 1/2‖, a swage connection should be
used on the suction port in order to maintain a 1 1/2‖ suction line size as near the gear
pump as possible.
B. A liquid filled vacuum gauge (0 to 30‖ Hg) should be installed as near the gear pump
suction port as possible in order to monitor the suction flow condition, especially during
cold startups in cold weather.
C. The gear pump may be direct coupled to an accessory drive location on the engine or
can be direct coupled to the transmission with a pump-mount type power take-off (PTO).
The transmission/PTO mount usually offers the advantage of a lower mounting and
improved suction conditions. The lube pump mounting must be a direct coupled positive
drive arrangement which operates at engine speed whenever the plunger pump’s prime
mover is running.

4. Lube system pressure lines and oil filter:

A. Pressure lines must be 3/4‖ I.D. minimum in order to maintain a flow a velocity of 10 to
12 ft. per second maximum.
B. Pressure lines should be wire reinforced with a minimum working pressure of 800 PSI.
C. The oil filter must be rated at 50 GPM/200 PSI minimum, must have a built-in 15 to 25

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 PSI relief valve, and 25 to 33 micron elements. The filter may be of either the spin-on
throw-away element type or the canister enclosed throw-away element type. The filter
must be located in an easily serviceable location and a built-in bypass indicator (service
indicator) is recommended. A dual element filter rated at more than 50 GPM will
decrease the pressure drop associated with filtering 90 weight gear oil and will increase
the time interval required between filter element changes. An external relief valve
should never be used to protect the filter.
D. A liquid filled 0 to 200 PSI oil pressure gauge must be located at the 1/2‖ NPT lube inlet
on the plunger pump. An auxiliary oil pressure gauge is also highly recommended for
those units having remote control console.

5． Lube system relief valve and relief return line:

a) The system relief valve should be a 3/4‖ 20 to 25 GPM, 60 PSI minimum/200 maximum,
adjustable non-chattering type relief valve.
b) The relief valve must be located at the plunger pump’s 1/2‖ NPT lube port (opposite the
lube inlet) to insure oil flow throughout the plunger pump before reaching the relief
valve.
c) Te relief return line should be 3/4‖ I.D. minimum, wire reinforced, rated at 800 PSI
minimum operating pressure; and should be return directly to the reservoir.

6． Lube drain lines (from plunger pump to reservoir):

a) WET/TWS600S is equipped with a 2‖ NPT drain port in the speed reducer housing and
a 3‖ NPT drain port in the bottom of the power end housing. The drain lines should
never be smaller than the drain port in the power end/speed reducer and should be as
short as possible. The drain lines should be free of excessive bends and kinks and should
flow continuously downhill to the reservoir. If necessary, the 2‖ drain line from the
speed reducer can be teed into a common 3‖ drain line returning to the reservoir. The
lowest 2‖NPT drain port in the speed reducer should always be utilized for the drain line
in order to prevent the speed reducer from accumulating excess oil.
b) A 0 to 250 F oil temperature gauge should be installed in the primary drain line such that
its sensor will be submerged in the return oil from the plunger pump. The temperature
gauge should also be located in a place easily accessible for viewing. An auxiliary oil
temperature gauge is also highly recommended for those units which have a remote
control console.

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7． Optional lube system equipment:
a) In extremely hot ambient conditions, an oil cooler may be required to prevent excessive
oil temperatures and inadequate oil viscosity. When used, the oil cooler should be of the
―air to oil‖ or ―forced air‖ type and should be located down-stream from the oil filter.
The cooler should be rated at 50 GPM/250 PSI minimum, and should have 3/4‖
minimum inlet and outlet connections. If the well service unit will also be subjected to
periods of cold weather, the oil cooler must be plumbed in a manner that will allow the
oil bypass the cooler when cold ambient conditions occur.
b) In extremely cold ambient conditions, the use of either an electronic sump heater or a
―tube and shell‖ heat exchange may be required to prevent extremely poor lube suction
conditions, lube pump damage, and plunger pump damage due to the lube oil becoming
too cold and viscous to flow properly. When used, the electronic sump heater should be
installed near the suction outlet in the oil reservoir and should be capable of heating the
oil to approximately 80 to 100 degrees Fahrenheit over an 8 to 12 hour period of time.
The sump heater must be thermostat controlled to prevent overheating the oil.

When using a ―tube and shell‖ type heat exchange for lube oil heating with engine jacket
water, the heat exchanger should be rated at 50 GPM/250 PSI (minimum) with 3/4‖
minimum inlet and outlet oil passage connections. The heat exchanger must be plumbed in
a manner that will allow it to be easily bypassed in the event the power end lube oil
temperature starts to exceed 180 degrees Fahrenheit.

Recommended Power End Lube Oils

Selecting the proper gear oil for satisfactory power end lubrication is very important to obtaining
long life and trouble-free service from the high performance WET/TWS600S plunger pump.
WETPUMP highly recommends the use of one of the modern synthetic gear lubricants which are
now available through all major lubricant markets. Synthetic lubricants exhibit a much more stable
viscosity over a wide range of ambient conditions. Synthetics also offer a much improved film
strength compared to a conventional gear oil of the same viscosity. The use of synthetic gear
lubricants will improve lubricant flow at pump startup, will provide superior wear protection, and
will result in higher hydraulic horsepower output due to reduced drag and friction between mating
parts.

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1. General service synthetic power end lubricants:
These gear oils must be rated for ―extreme pressure (EP)‖ service, must have a ―viscosity index‖
of 135 or higher, must have a ―pour point‖ of –35 degree F or lower, must have a ―Timken Test‖
rating of 50 lbs. or higher, and must have a ―viscosity‖ of 125 SUS or higher at 210 degrees F. The
operating temperature of plunger pump must not exceed 180℉

2. Alternate seasonal non-synthetic power end lubricants:

―Conventional‖ non-synthetic gear oil may be used in WET/TWS600S plunger pump; however
more care must be taken in selecting the proper grade of oil to use for the prevailing ambient
conditions during a given season of the year. In all cases, a conventional gear lubricant must
contain an ―extreme pressure (EP)‖ additive, must meet or exceed U.S. Mil-Spec.Mil-L-2105B,
and must have a Timken Test rating of 45 lbs. or higher. Following is a list of the various brands
and grades of conventional gear lubricants which may be used seasonally as indicated:

A. Alternate moderate service (for spring and fall ):

These gear oils are suited for use in moderate ambient temperatures which range from 32
degrees F to 90 degrees F. These oils must have a ―pour point‖ of 0 degrees F or lower and
must have a ―viscosity‖ of 85 SUS or greater at 210 degree F. the plunger pump’s operating
temperature must not exceed 175 degrees F.
B. Alternate high temperature service (for summer or tropical climates):
These gear oils are suited for use in moderate ambient temperatures which range from 40
degrees F to 110 degrees F. These oils must have a ―pour point‖ of 20 degrees F or lower
and must have a ―viscosity‖ of 125 SUS or greater at 210 degree F. the plunger pump’s
operating temperature must not exceed 195 degrees F.

C. Alternate low temperature service (for winter):

WET/TWS600S highly recommends the use of a ―resultant pressure gear oils‖ to any
plunger pump under frigid atmosphere. These gear oils are suited for use in low
temperature service which range from -15 degrees F to 70 degrees F. These oils must have a
―pour point‖ of -20 degrees F or lower and must have a ―viscosity‖ of 75 SUS or greater at
210 degree F. the plunger pump’s operating temperature must not exceed 130 degrees F.

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 Power End Lube Startup and Performance Data

A properly designed lube system should require adjustments to the system only once---at the well
service unit’s original startup. Following are WETPUMP recommended guidelines for making
the initial adjustments as well as the lube system’s operating specifications:

1. Initial Lube System Adjustments And Specifications:

A. Fill the power end lube oil reservoir with the proper grade of EP gear oil for the existing
ambient conditions. Do not over-fill the reservoir--- the proper oil level should always
leave approximately 10% air space above the fluid level. For example, only 45 gallons
of oil should be used in a reservoir which has a 100% internal capacity of 50 gallons.
Disconnect the lube oil suction hose at the lube oil suction inlet and fill the hose w/gear
oil to prime the lube pump. Reinstall and tightened the suction hose.

B. With the plunger pump’s transmission in neutral, start the engine and run at idle only. It
will take a few minutes to pump oil through the entire system completely filling all lines,
filters, etc. during which time a thorough check should be made for oil leaks at hose
connections, etc. after all the lines are filled, the system should begin to show pressure
on the gauge at the system of air. Operate the engine for more than 5 minutes to
eliminate the air. Kill the engine and add oil to the reservoir in order to bring it back to
the full level.

C. With the transmission in neutral, restart the engine. Rev the engine up to full RPM
gradually while checking both the vacuum gauge at the lube pump suction inlet and the
pressure gauge at the plunger pump lube inlet. If the lube oil is warm enough and thin
enough, the vacuum reading will not exceed 10‖ Hg. If the lube oil is too cold and too
viscosity, reduce the engine speed and make the vacuum reading drop to 10‖ Hg. The oil
will eventually warm up just from the friction of traveling through the lube system and
through the plunger pump.

When the vacuum reading no longer exceeds 10‖ Hg at full engine RPM, adjust the lube
system relief valve so that the lube pressure does not exceed approximately 150 to 175
PSI at full engine RPM.
Note: The oil filter is usually the lowest pressure rated component in the lube system. The system
relief valve setting is made primarily to protect the oil filter and can be a higher setting than 175

21
PSI as long as it does not exceed the lowest rated component in the system. The plunger pump
itself will not be damaged unless the oil pressure exceeds approximately 400 PSI.

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

2. Power End Lube System Operation Specification:

Power end lube system readings will vary considerably due to the extreme viscosity changes in the
gear oil as it warms and thins from a cold startup till it reaches full operating temperature. The
system pressure and vacuum variations are caused by the extreme viscosity changes in the oil. The
type SEA90wt. Gear oil even at room temperature is very viscous (much likes molasses), creates
much resistance to flow in the system, and creates high system pressures even at very low lube
flow rates. Likewise, the typical SAE 90wt. gear oil at 150F to 175F becomes much less viscous,
flows very freely, and creates much less resistance in the system showing up as considerably lower
system pressures.

Due to the extreme viscosity changes in the gear oil and due to the many different possible system
designs, it is difficult to establish a firm set of system readings which will be highly accurate for
every system. Each system will vary somewhat especially in the area of stabilized temperature and
pressure readings during full horsepower or full torque plunger pump operation. The system
specifications herein should be observed in addition to each unit’s normal system characteristics
after having been put into service.

Maximum Acceptable Vacuum Reading

While Operating the WET/TWS600S Plunger Pump

At Lube Pump Suction Inlet at Any Time--------------------------------10‖ mercury column

Maximum Oil Pressure at Cold Startup and Full Engine RPM-------------175PSI

While Operating the WET/TWS600S Plunger Pump

Maximum Oil Temperature at Any Time:
With General Service SEA 90 Gear Oils ----------------------------- 175°F
With Cold Weather SEA 80 Gear Oils--------------------------------- 130°F
With Hot Weather SEA 140 Gear Oils--------------------------------- 195°F

22
 Approximate Normal Oil Pressure at Stabilized Operating Temperature
and Full Engine RPM --------------------------------------------------- 70～100PSI
While Operating the Plunger Pump at Full Engine RPM:
Minimum Oil Pressure at Any Time and stabilized Working Temperature---------- 40PSI

Note: Any sudden vacuum, pressure or temperature deviations from normal (especially if
accompanied by any usual noise, vibration or smoke) indicate the need to cease pumping
operations and investigate the problems before power end damage occurs. (See trouble shooting
section of this manual)

23
 Plunger Pump System Requirements

WET/TWS600S well service plunger pumps are designed for packing lubrication with oil rather
than grease. Exceptionally long packing life can be excepted providing proper lubrication is
supplied to the plunger packing lube port above each stuffing box. Ample plunger and packing
lubrication can be achieved with an inexpensive relatively trouble-free low-pressure air operated
lubricant pump type system. Mechanically driven plunger lubricators are not recommended due to
the well service pump’s extreme variations in pump speeds. A properly designed packing lube
system will meet the following specifications:

1. Oil reservoir:
A. Should be of approximately 5-gallon capacity.
B. Should be equipped for the vertical installation of an air-operated pump.
C. Should be equipped with a dipstick or sight glass.
D. Should be equipped with a breather/filler cap that has a built-in strainer to prevent trash
from entering the reservoir.

2. Air operated lubricant pump:

A. Vertical air operated 12 oz. per minute/150 PSI/40:1 ratio lubricant pump.
B. Must be equipped with a 1/4‖ adjustable air pressure regulator in order to adjust the
pump speed and packing lubricant flow rate.
C. Should be installed so that the bottom of the pump is no closer than 1‖ to the bottom of
the reservoir.

3. In-line relief valve:

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

24
4. Packing lubricant flow lines:
A. Should be 1/4‖ I.D./1250 PSI minimum/fiber or wire reinforced hose to prevent
crimping.
B. Should be a common line from the lubricant pump to the plunger pump at which point it
will branch off to each individual packing lube port.

5. Speed control valve:

A. Should be a 1/4‖ speed control valve, which can be locked at any given setting after
adjustment.
B. Must be installed in each lubricant flow line which leads to the individual packing lube
ports in the plunger pump fluid cylinder.

6. High pressure check valve:

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

7. Packing lube system flow requirements/adjustments:

After filling with the proper grade of packing lubricant rock drill oil, and before rotating the
well service plunger pump, the line leading to each plunger port should be bled-off at the
connection leading into each check valve.
A. Packing without wiper ring:
The lube system should be adjusted so that oil drops rapidly from the packing nut at each
plunger. The flow should then be adjusted so that the drips occur only once every second.
Each plunger and packing assembly requires approximately 437ml per hour in order to be
properly lubricated.
B. Packing with wiper ring:
All pumps (with a rod wiper) require a 30psi limit to the plunger lubrication system.
Adjust the lube relief to 30psi maximum. Exceeding 30psi may cause premature failure of
the wiper ring.

25
 Recommended Plunger Lube Oils

Selecting the proper plunger lube oil is very important to obtaining long life from the pumps
plungers and packing assemblies. The use of a superior plunger lubricant will also reduce
horsepower robbing friction, reduce fuel consumption, and increase the net amount of hydraulic
horsepower delivered by the pump. WET PUMP highly recommends the use of a modern cutting
tool oil for improved lubrication of the plungers and packing. In an area where this kind of oil is
not available, suitable oil may be substituted. For common operation, the ambient temperature is
always above 32°F.
Note：
Proper lubrication is critical during the startup of the plunger pump. The plunger lubricant
must begin to flow freely to the stuffing box lube inlet prior to the pump’s startup and
stroking of the plungers.

Pumps which have sat idle for any appreciable period of time (two weeks or more) must
have the plunger removed, be coated with plunger lube oil, and reinstalled prior to operation
under power. The rubber packing rings will eventually stick to the plunger surface and will
become damaged upon startup if not re-lubricated as noted above.

Although conditions will vary, only approximately one pint of lubricant per hour per plunger
is required for adequate lubrication. A minimum of 20 drops of oil per minute per plunger is
required. When using an air operated plunger lube system, the audible sound of the air
operated lubricant pump stroking once every one to two seconds will be indicator of
satisfactory plunger and packing lubrication.

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

WETPUMP recommends the use of ROCK BIT or WAY OIL that meets the following
specifications:

ISO Grade 32 68
CPS No. 232500 232511
AGMA Grade —— 2

26
 API Gravity 21.4 25.6
Viscosity, Kinematics
CSc at 40oC 30.4 64.6
CSc at 100oC 4.9 7.3
Viscosity, Saybolt
SUS at 100oF 158 338
SUS at 210oF 42.7 50.8
Viscosity Index 74 61
Flash Point, C (F) 170 (338) 200 (389)
Pour Point, C (F) -45 (-48) -24 (-11)

Lubricants that fail to meet these specifications, and especially used crankcase oils are
unacceptable.

Startup is a critical time for plunger packing. Lubrication should flow freely to plunger prior
to stroking the pump. Although conditions will vary, generally twenty drops per minute lube
oil rate is recommended. Stroking dry plungers can cause the header ring and packing to tear
and fail.

Chapter 7 Supercharging System Requirements

Due to the high speed design characteristic associated with well service plunger pumps,
supercharging the WET/TWS600S is a must. The nature of well service operations (extreme
variations in flow rates coupled with the pumping of heavy slurries) requires a well designed
supercharge system. The supercharging system must deliver an adequate supply of liquid to the
plunger pump’s suction manifold at high enough pressures and low enough flow velocities high
enough to keep solids suspended in the fluid slurry. A well designed supercharging system is
extremely important in avoiding the harmful effects of cavitations and insuring trouble-free
service from the WET/TWS600S. A well designed supercharging system will meet the following
guidelines.

1. Primary Suction Piping and Hoses:

There are defined as the piping where the fluid first begins to flow from its source through gravity
flow or atmospheric pressure only. This portion of the system is usually a pipe or hose which

27
connects the fluid reservoir to the charge pump or in some cases to a mixing pump. The flow
velocity based on the plunger pump’s maximum flow rating with the size plunger being used in
this portion of the system must not exceed 4 ft. per second in order to flow freely under
atmospheric pressure or gravity flow. Other guidelines are as follows:
A. The hoses must be oil and chemical resistant wire reinforced combination
vacuum/discharge hose rated at 30‖ Hg/60 PSI minimum.
B. If steel piping is used, all piping runs must be installed so that they are level or
progressively higher toward the plunger pump in order to prevent air traps in the system.
When used, reducer fitting should be of the eccentric type and installed ―belly down‖ in
order to prevent air traps. All welded connections must be air and fluid tight.
C. All piping or hoses in this portion of the system should be kept as short as possible (10
ft. or less) and should be free of excessive bends and turns.

2. Centrifugal Supercharge Pump/Mixing Pump:

Some well servicing operations require the use of two centrifugals –one for mixing slurry and the
other for supercharging the plunger pump. When two centrifugals are used, they must both meet
the following guidelines:
A. Must be capable of delivering the rated maximum flow of the plunger pump while
maintaining 30 PSI (69 ft. head) at the plunger pump suction inlet.
B. Must be sized appropriately to overcome any friction losses in the piping between the
centrifuge’s discharge and the plunger pump’s suction inlet. For example, depending on
the length and the layout of the piping, the centrifugal may have to be sized to deliver
the required flow at 50 PSI (115 ft. head) at its discharge in order to maintain 30 PSI (69
ft. head) at the plunger pump suction inlet.
C. Must be operated at a speed which will deliver the requires flow within the upper 15%
of its efficient range in order to assure adequate fluid acceleration on demand from the
plunger pump.
D. Must be adequately powered to deliver the plunger pump’s fluid requirements based on
volume, pressure and specific gravity of the fluid or slurry.

3. Secondary Suction Piping and Hoses:

These are defined as the piping which carries fluid under pressure from the centrifugal pump’s
discharge to another point in the system. This is the piping which connects the centrifugal charge
pump to the plunger pump suction inlet and can also be the piping which connects the centrifugal

28
mixing pump’s discharge to a mixing tub inlet. The flow velocity in this portion of the system
(based on the plunger being used) should range from 8 to 12 ft. per second. Other guidelines are as
follows:
A. Hoses must be oil and chemical resistant wire reinforced combination vacuum/discharge
hose rated at 30‖ Hg/60 PSI minimum.
B. If steel piping is used, all piping runs must be installed so that they are level or
progressively higher toward the plunger pump in order to prevent air traps in the system.
When used, reducer fitting should be of the eccentric type and installed ―belly down‖ in
order to prevent air traps. All welded connections must be air and fluid tight.
C. All piping or hoses in this portion of the system should be kept as short as possible (10
ft. or less) and should be free of excessive bends and turns.
4. Suction Pulsation Dampener:
Due to the plunger pump’s positive displacement design, a naturally occurring fluid rhythm is
generated in the supercharge system as the fluid stops and starts underneath each suction valve.
The varying pressure signal created by this fluid rhythm reduces the effectiveness of the charge
pump unless the pressure signal is dampened out of the system. A suction valve opens, will help
prevent cavitations, and will result in a much smoother operating pump. Guidelines for using a
suction pulsation dampener are as follows:
A. The pulsation dampener should be of the nitrogen charged bladder type rated at 100 PSI
minimum.
B. Should be installed above the fluid flow path so that solids in the fluid cannot settle and
pack around the bladder.
C. Should be installed as close to the plunger pump’s suction inlet as possible for
maximum effectiveness.
D. Must be pre-charge according to the manufacturer’s recommendations (usually 30% to
40% of the anticipated supercharge pressure).

5. Supercharge Pressure Gauge:

A supercharge pressure gauge should always be used in the system and should meet the following
guidelines:
1. Should be a liquid filled 0 to 100 PSI pressure gauge.
2. Should be installed as close to the plunger pump suction inlet as possible for maximum
accuracy.
3. Should be used with a measuring vibration isolator or a speed control valve which can

29
 be adjusted to act as a buffer.

Supercharging System Operational Parameters

1. Recommended supercharge pressure at plunger pump suction inlet: 30 PSI (69 ft. head)
minimum to 80 PSI (185 ft. head) maximum.
Note: The supercharge pressure must always be higher than the vapor pressure of the fluid
being pumped.

2. Number of 4‖ suction hoses required to maintain 4 ft. per second maximum fluid velocity in
―gravity feed‖ portion of the system.

Number Of 4‖
GPM Flow BPM Flow
Hoses REQ’D
Up to 157 3.74 1
Up to 313 7.45 2
Up to 470 11.19 3
Up to 626 14.90 4
Up to 783 18.64 5

3. Steel pipe size required to maintain 4 ft. per second maximum fluid velocity in ―gravity feed‖
portion of the system.
Number Of 4‖ Hoses
GPM Flow BPM Flow
REQ’D
Up to 156 3.71 Inside diameter 4‖
Up to 250 5.95 Inside diameter 5‖
Up to 353 8.40 Inside diameter 6‖
Up to 626 14.90 Inside diameter 8‖
Up to 979 23.31 Inside diameter 10‖

4. 4‖ suction hoses required to maintain 12 ft. per second maximum fluid velocity in
―pressurized‖ portion of the system.
Number Of 4‖ Hoses
GPM Flow BPM Flow
REQ’D

30
 Up to 470 11.19 1
Up to 940 22.38 2
5. Steel pipe size required to maintain 12 ft. per second maximum fluid velocity in
―pressurized‖ portion of the system.
Number Of 4‖ Hoses
GPM Flow BPM Flow
REQ’D
Up to 264 6.29 ID3‖
Up to 470 11.19 ID4‖
Up to 734 17.48 ID5‖

6. Flow Velocity Formula:

A. To calculate the fluid velocity when the GPM and internal area of pipe or hose are
known:
GPM×0.3208 divided by area = Velocity in ft. per sec.
B. To calculate the maximum GPM to maintain a specified flow velocity when the velocity
desired and the internal area of the pipe or hose is known:
Velocity× area divided by 0.3208 = GPM

Chapter 8 Operation and maintenance of pump

WET/TWS600S Pump start-up and shut-down Procedure

Each new pump must undergo a brief but thorough start-up and shut-down procedure in order to
verify the field worthiness of the unitized pumping system and in order to allow a gradual
―wearing in‖ of various mating parts in the pump itself. The following guidelines have been
established by SJPETRO to minimize startup problems and insure maximum service from the
plunger pump:

A. Inspection prior to starting engine:

1. Check to see that all masking tape, rust preventative, etc. has been removed from
moving parts such as plungers, pinion shaft, etc.
2. Check to see that the plunger pump is securely bolted to skid rail or truck frame.
3. Check to see that the driveline is securely fastened to the plunger pump’s input shaft and
that adequate slip is present in the driveline’s slip joint.

31
 4. Check to see that the power end lube oil reservoir was flushed and drained, then filled
with the proper type of gear oil.
5. Check to see that the plunger lube oil reservoir was flushed and drained, then filled with
the proper type of rock drill oil.
6. Check to see that the supercharging pipe system has been completely flushed and all
piping connections are tight.
7. Check to see that the power end lube system startup adjustments and plunger lube
system startup adjustments were performed.
8. Check to see that the suction pulsation dampener has been per-charged properly.
9. Check to see that the primary suction piping is connected to an adequate supply of cool
clean water for testing.
10. Check to see that the plunger pump’s discharge piping is safely installed all the way
back to the water reservoir. Check to see that all connections are tight and all valves are
open.
11. Start the supercharge pump and flush all air from the entire system.
12. Follow the engine manufacturer’s recommendations for engine startup and warm up.

B. Warm up procedure prior to rotating the plunger pump:

1. While operating the engine at idle and transmission in neutral, check the power end lube
pump vacuum reading, the power end lube oil pressure, and the power end lube oil
temperature. If the lube pump vacuum reading is less than 10‖Hg, gradually increase the
engine RPM to determine whether full engine RPM can be reached without exceeding
10‖Hg at the power end lube pump suction inlet.
2. Continue running the engine at or below 10‖Hg lube pump vacuum as necessary to
warm and thin the power end lube oil. The plunger pump should not be rotated until full
engine RPM can be achieve without exceeding 10‖ Hg at the lube pump suction inlet or
until the power end lube oil temperature reaches 60F minimum.
3. During this portion of the startup procedure, closely observe the plunger pump for any
unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information such
as elapsed time, ambient temperature, power end lube oil temperature, power end lube
oil pressure, supercharge pressure, etc. After returning the engine to idle and
transmission to neutral, physically inspect the plunger pump before proceeding further.

C. Working Condition

32
Run the plunger pump at this setting for 30 minutes. During this time, closely observe the plunger
pump for any unusual noise, vibration, fluid leaks, and oil leaks. Record all pertinent information
such as elapsed time, ambient temperature, power end lube oil temperature, power end lube oil
pressure, supercharge pressure, etc. After returning the engine to idle and transmission to neutral,
physically inspect the plunger pump before proceeding further. Pay attention to the following
notes:

 Visually inspect the power end for oil leaks around the plunger seals, pinion seal, lubrication
hoses, lube drain hose, covers, etc.
 Visually inspect the fluid end for fluid leaks around the suction covers, discharge covers,
discharge flanges, stuffing boxes, and suction manifold. Visually inspect the plungers for any
signs of heating or scoring.
 Remove the power end lube system magnet and inspect for any unusually large particles of
metal. Change the lube oil-filters.
 Pressure is limited to 15,000PSI due to discharge flange and plunger configuration.

33
 Recommended Practice for Pump Packing

1. Cement Service
Usually a remedial process which places a cement slurry near an opening in the well. The fluid is
then pumped using hydraulic pressure to force or ―squeeze‖ the slurry against the formation either
in open hole, through perforations, or a hole in the casing.
In practice most cement jobs are at relatively low pressure, but high rates requiring modest power
to the pump.

Packing: “rubber spring loaded” (see fig. 1)

Plunger sealing packing is mainly made of the following parts：

5、Header Ring 6、Pressure Ring 7、Spacer Ring 8、Oil Seal

Installation and Adjustment for Packing

Roughness of plunger surface is critical for packing service life.Upon installation, great

cared need to be taken of and not damage the packing. Before installation, ensure the packing box

is clean and clear and coat the lube oil on the packing and inside the packing box as well as on the

thread. Clean the burr and tip angle on the plunger surface.

Installation Procedure：

1、 Screw the packing nut and make the packing as tight as possible.

2、 Loosen the packing nut.

3、 Screw the packing nut again,making packing nut and packing set just connect.

4、 Screw the packing nut into 1-2mm (about 1/4 turn). Mark a line at the packing nut and

cylinder.

5、 Rollback the pakcing nut about 1/2 turn and install the plunger.

6、 Tight the packing nut and make it align to the marking line.

7、 Not adjust.

34
During the use, the air pressure shall be adjusted to 0.20－0.25Mpa with lube oil volume 20－

25ml/min.

Fig 1

35
 Trouble-shooting Guide

Trouble Symptom: Probable Cause:

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

36
 Trouble Symptom: Probable Cause:
E.) Leaking fluid end seals. 1. Seal installed improperly.
2. Seal cut or pinched on installation.
3. Mating seal surface not cleaned properly prior to seal
installation.
4. Damaged or corroded mating seal surface.
5. Sealing part not properly tightened.
F) Plunger and/or packing fluid 1. Packing nut not tightened properly.
leak. 2. Worn or damaged packing.
3. Packing installed improperly.
4. Mating seal surface not cleaned properly prior to packing
installation.
5. Damaged or corroded mating seal surface.
6. Fluid being pumped is incompatible with the style packing
being used.
G) Fluid knock or hammer. 1. Air entering supercharge system through loose, worn or
damaged connections.
2. Air entering supercharge system through leaking charge
pump seals.
3. Fluid being pumped contains gas or vapor.
4. Insufficient supercharge flow or pressure.
5. Valve cocked open/broken valve spring or valve stop.
6. Worn or damaged valve, valve insert, or valve seat.
7. Improperly charged or ineffective suction pulsation
dampener.
H) Low discharge 1. Worn or damaged valve, assembly.
pressure/rough running pump. 2. Insufficient supercharge flow or pressure.
3. Air, gas, or vapor in fluid being pumped.
4. Improperly charged or ineffective suction pulsation
dampener.
5. Two or more plunger pumps being supercharged by a
common charge pump and being allowed to get ―in phase‖
with each other.

37
 Routine Preventive Maintenance

Maximum service and trouble-free operation can be obtained from the WET/TWS600S well
service plunger pumps by establishing a thorough preventive maintenance program as follow:

A. During the first 100 hours of new pump operation:

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

B. Daily preventive maintenance:

1. Check the oil level in the power end lube oil reservoir.
2. Check the oil level in the plunger lube oil reservoir.
3. Check the plunger pump for oil leaks and/or fluid leaks.
4. Check the power end lube oil system for leaks.
5. Check the plunger lube system for leaks.
6. Check the supercharge piping for leaks.

C. Weekly preventive maintenance:

1. Check all items on daily list.
2. Check all valves, inserts, valve seat sand springs.
3. Check all discharge and suction cover seals.
4. Check suction pulsation dampener for correct pre-charge.

D. Monthly (or every 100 hours) preventive maintenance:

1. Check all items on daily and weekly lists.
2. Check all fluid cylinder mounting bolts to insure that they are tight.
3. Check all plunger pump mounting bolts to insure that they are tight.
4. Change power end lube oil filters.
5. Check all supplies needed for routine maintenance such as o-rings, fluid seals, valves,
valves inserts, valve seals, valve springs, packing, oil seals filter elements, etc.
E. Quarterly (or every 250 hours) preventive maintenance:

38
 1. Check all items on daily, weekly and monthly list.
2. Change the power end lube oil and refill with the proper grade of gear oil for upcoming
ambient conditions.
3. Thoroughly clean the power end lube oil suction strainer.
4. Remove and inspect the plungers and packing assembly components. Replace all packing
pressure rings and header rings.
5. Clean the plunger pump’s oil breather and the power end lube oil reservoir breather.

F. Yearly (or as required) preventive maintenance:

1. Replace worn plungers and packing brass.
2. Replace worn or corroded valve covers, suction valve stop, packing nuts, discharge flange,
pump tools etc.
3. Replace all discharge flange seals and suction manifold seals.
4. Replace any defective gauges and instruments.
5. Inspect (and rebuild if necessary) the power end lube oil pump.

It is difficult to assess wear and tear on a pump based solely on hours operated, due to the
variations in duty cycle and types of service.

However, roller bearings and gearing may need replacing after approximately 3000 hours. With
these components, signs of extensive wear will generally show up as scaling off (or flaking off), of
material causing pitting or scoring on the working surfaces. All small amount of this is tolerable
on gear surfaces, but any scaling off on a bearing surface is an indication to replace that item as
quickly as feasible.

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

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

Torque Table

39
 Cap screws, nuts & bolts (See grade 5) Alloy steel studs & nuts (See grade 7)

Thread dia. & Dry threads Lubricated threads Dry threads Lubricated threads
thread pitch torque (ft. lbs) torque (ft. lbs) torque (ft. lbs) torque (ft. lbs)

1/4-20 UNC 6.7 5.1 — —

5/16-18 UNC 13.9 10.4 — —
3/8-16 UNC 24.7 16.5 — —
7/16-14 UNC 39.4 29.6 — —
1/2-13 UNC 60.3 45.2 — —
5/8-11 UNC 110.0 80.0 — —
3/4-10 UNC 212.0 159.0 — —
7/8-9 UNC 315.0 236.0 425.0 318.0
1-8 UNC 472.0 354.0 635.0 477.0
1 1/8-7 UNC 633.0 475.0 900.0 675.0
101/4-7 900.0 675.0 1270.0 955.0
1 3/8-8 NS — — 1660.0 1245.0
1 5/8-8 NS — — — 2300.0
1 3/4-8 NS — — — 2400.0

To obtain the required torque on the 1 3/8‖, 1 5/8‖ and 1 3/4‖ studs, when a torque wrench is not
available, use a hammer lug wrench. After tightening with a standard wrench, turn the nut another
30 degrees (1/12th turn) with the hammer wrench.

40
Chapter 9 Consumable Parts List

1 .3 1/2‖ 600 plunger pump

Price
Item Model Description Material Qty
（usd）

1 CKTWS600S-3.5-1 Fluid End CZNi-25(N14) 1

O Ring, Valve
2 CKTWS600S-3.5-2 NBR 6
Seat

3 CKTWS600S-3.5-3 Valve Seat 8620H 6

4 CKTWS600S-3.5-4 Valve Insert TPU 6

5 CKTWS600S-3.5-5 Valve Body 8620H 6

Discharge
6 CKTWS600S-3.5-6 302 3
Spring

Seal, Discharge
7 CKTWS600S-3.5-7 NBR 3
Cover

Circlip,
8 CKTWS600S-3.5-8 PTFE 3
Discharge Cover

9 CKTWS600S-3.5-9 Discharge Cover 4340/4140 2

Discharge

10 CKTWS600S-3.5-10 (suction) 4340/4140 5

Retainer

O Ring, Packing
11 CKTWS600S-3.5-11 NBR 3
Set

41
 O Ring
12 CKTWS600S-3.5-12 NBR 3
II,Packing Set

13 CKTWS600S-3.5-13 Packing set 4140 3

14 CKTWS600S-3.5-14 Header Ring Nbr 3

15 CKTWS600S-3.5-15 Pressure Ring HNBR 3

16 CKTWS600S-3.5-16 Bush ring ZCuAL9-4-4-2 3

17 CKTWS600S-3.5-17 Lattern Ring ZCuAL9-4-4-2 3

18 CKTWS600S-3.5-18 Plunger 5140 3

Oil Seal, Plunger

19 CKTWS600S-3.5-19 NBR 3
Retainer

20 CKTWS600S-3.5-20 Retainer, Plunge 4340/4140 3

21 CKTWS600S-3.5-21 Suction spring 302、304 3

Lower Spring
22 CKTWS600S-3.5-22 ZG5140 3
Seat

Seal, Discharge
23 CKTWS600S-3.5-23 NBR 3
Cover

24 CKTWS600S-3.5-24 Discharge Cover 4340/4140 3

Discharge
25 CKTWS600S-3.5-25 QZNi-25 2
Flange

O Ring,

26 CKTWS600S-3.5-26 Discharge NBR 2

Flange

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 O Ring, Flange
27 CKTWS600S-3.5-27 NBR 2
Head Face

28 CKTWS600S-3.5-28 2" Union Seal NBR 3

Nut,Discharge
29 CKTWS300-3.5-29 4340/4140 8
Flange

30 CKTWS600S-3.5-30 Flat Spacer Q235 8

31 CKTWS600S-3.5-31 Stud 4340/4330 8

Transducer
32 CKTWS600S-3.5-32 CZNi-25 1
Connector

Circlip, Packing
33 CKTWS600S-3.5-33 PTFE 3
O RingⅠ

Circlip, Packing
34 CKTWS600S-3.5-34 PTFE 3
O RingII

35 CKTWS600S-3.5-35 Header Ring II HNBR 3

36 CKTWS600S-3.5-36 Pullrod big 42crmo 4

37 CKTWS600S-3.5-37 Pullrod small 42crmo 4

Chapter 10 Accessories and Tools

WET/TWS600S pump accompanied accessories and tools:

Item No. Description Qty Remarks

1 Wrench, Packing Retainer 1 ea Tool
2 Ejector Rod, Suction Valve 1 ea Tool

3 Puller, Valve Cover 1 set Tool

4 Allen Wrench 1 set Tool

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5 Wrech, Plunger 1 set Tool

6 Installation Tool,Valve Insert 1set Tool

44