Serva - Qpa1000 061814

QPA1000
QUINTUPLEX PUMP
SERVICE MANUAL
VOLUME 1
1045 Keystone Ave. Phone: 918-266-070

Catoosa, OK 74015 FAX: 918-266-079
www.servagroup.com Email: info@servagroup.com
©SERVAgroup, LLC 2014 A08012970E__C_en
QPA1000 Quintuplex Pump
Service Manual
Volume 1 of 1
©
2014, SERVAgroup, LLC. All rights reserved. Printed in the United States of America.
Information in this document is subject to change without notice. No part of this document or any associated
software may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any
purpose other than as permitted in the license agreement, without the written permission of
SERVAgroup, LLC.

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CONTENTS
CONTENTS ............................................................................................................................. III
LIST OF FIGURES .....................................................................................................................V
LIST OF TABLES ..................................................................................................................... VI
1.0 GENERAL INFORMATION ...............................................................................................1
1.1 Safety Precautions...................................................................................................1
1.2 QPA1000 Pump Description ....................................................................................2
1.2.1 Performance Data 1..................................................................................3
1.2.2 Performance Data 2..................................................................................4
1.2.3 Tachometer Drive/Rate Meter Calibration Specifications .........................4
1.2.4 Identification Plate ....................................................................................5
1.2.5 Pump Noise ..............................................................................................5
1.3 Replacement Parts ..................................................................................................6
1.4 Shipping and Storage ..............................................................................................6
2.0 INSTALLATION DETAILS ................................................................................................9
2.1 Pump Installation Highlights ....................................................................................9
2.1.1 Power Source ...........................................................................................9
2.1.2 Drivetrain ..................................................................................................9
2.1.3 Power End Mounting ..............................................................................10
2.1.4 Power End Lubrication............................................................................10
2.1.5 Plunger Lubrication .................................................................................10
2.1.6 Super-charging System ..........................................................................10
2.2 Installation Detail Drawing .....................................................................................11
2.3 Start-up and Break-in Procedure ...........................................................................12
2.3.1 Inspection Procedure ..............................................................................12
2.3.2 Warm-up Procedure (prior to rotating the plunger pump) .......................13
2.3.3 Plunger Pump Valve Seating Procedure ................................................13
2.3.4 Break-In Procedure.................................................................................14
3.0 POWER END LUBE SYSTEM REQUIREMENTS ...............................................................17
3.1 Oil Reservoir ..........................................................................................................18
3.2 Lube Pump ............................................................................................................18
3.3 Lube System Pressure Lines and Oil Filter ...........................................................19
3.4 Lube System Suction Lines and Oil Filter ..............................................................21
3.5 Lube System Relief Valve and Relief Return Line .................................................21
3.6 Lube Drain Lines (from Plunger Pump to Reservoir) .............................................21
3.7 Optional Lube System Equipment .........................................................................22
3.8 Recommended Power End Lube Oils....................................................................23
3.8.1 General Service Lube Oils ......................................................................23
3.8.2 Extreme Cold Weather Lube Oils ...........................................................23
3.8.3 Extreme Hot Weather Lube Oils .............................................................24
3.8.4 Power End Lube System Operation Specifications ................................24
4.0 PLUNGER LUBE SYSTEM PUMP REQUIREMENTS .........................................................27
4.1 Oil Reservoir ..........................................................................................................27
4.2 In-Line Relief Valve................................................................................................27
4.3 Flow Control Needle Valves ..................................................................................27
4.4 High Pressure Check Valves .................................................................................28
4.5 Recommended Plunger Lube Oils .........................................................................28
5.0 TROUBLESHOOTING GUIDE ........................................................................................29
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6.0 ROUTINE MAINTENANCE.............................................................................................31

7.0 FLUID END REPAIR PROCEDURES ..............................................................................35
7.1 Remove Valves and Seats ....................................................................................35
7.2 Change Plungers and Packing ..............................................................................36
7.3 Remove Discharge Flanges ..................................................................................38
7.4 Remove the Suction Manifold ................................................................................38
7.5 Remove the Fluid End ...........................................................................................39
7.6 Power End Repair Procedures ..............................................................................40
7.6.1 Remove and Disassemble the Speed Reducer ......................................40
7.6.2 Remove the Crankshaft, Connecting Rods, and Crossheads ................42
8.0 TORQUE TABLE .........................................................................................................45
9.0 POWER END ASSEMBLIES AND DETAILED PART LISTS ................................................46
9.1 Power End Case Assembly ...................................................................................46
9.2 Crankshaft Assembly .............................................................................................48
9.3 Crosshead Connecting Rod Assembly ..................................................................50
9.4 Gear Reducer Assembly........................................................................................52
9.5 Gear Reducer Lube Assembly...............................................................................54
10.0 FLUID END PARTS ......................................................................................................56
10.1 Fluid End Assembly ...............................................................................................56
10.2 D-Ring Packing Assembly .....................................................................................61
10.3 O-Ring & Backup O-Ring Packing Assembly ........................................................62
10.4 Packing Assembly 3” .............................................................................................63
10.5 Packing Assembly 3 1/2” .........................................................................................64
10.6 Packing Assembly 4” .............................................................................................65
10.7 Packing Assembly 4 1/2” .........................................................................................66
10.8 Seal Assembly .......................................................................................................67
11.0 ACCESSORIES ...........................................................................................................69
11.1 Useful Pump Data Terms ......................................................................................69
11.2 Pump Data Formulas .............................................................................................70
12.0 TOOLS .......................................................................................................................73
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LIST OF FIGURES
Figure 1 - Oil Inlet Connection............................................................................. 20
Figure 2 - Lube Assembly, Power End ................................................................ 20
Figure 3 - ISO Grade Fluid Chart ........................................................................ 26
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LIST OF TABLES
Table 1 - First 100 Hours of New Pump Operation ............................................. 31
Table 2 - Daily ..................................................................................................... 31
Table 3 - Weekly ................................................................................................. 31
Table 4 - Monthly (or Every 100 Hours) .............................................................. 32
Table 5 - Quarterly (or Every 250 Hours) ............................................................ 32
Table 6 - Yearly (or as required) ......................................................................... 32
Table 7 - Power End Case Assembly Parts List.................................................. 47
Table 8 - Crankshaft Assembly Parts List ........................................................... 49
Table 9 - Crosshead Connecting Rod Assembly Parts List ................................ 51
Table 10 - Gear Reducer Assembly Parts List .................................................... 53
Table 11 - Gear Reducer Lube Assembly Parts List ........................................... 55
Table 12 - 3” Fluid End Assembly Parts List ....................................................... 57
Table 13 - 3 ½” Fluid End Assembly Parts List ................................................... 58
Table 14 - 4” Fluid End Assembly Parts List ....................................................... 59
Table 15 - 4 ½” Fluid End Assembly Parts List ................................................... 60
Table 16 - Packing Assembly Parts List (3”) ....................................................... 63
Table 17 - Packing Assembly Parts List (3 1/2”) ................................................... 64
Table 18 - Packing Assembly Parts List (4”) ....................................................... 65
Table 19 - Packing Assembly Parts List (4 1/2”) ................................................... 66
Table 20 - Seal Assembly (used before 2007) .................................................... 67
Table 21 - Current Set Seal Assembly (used since 2007) .................................. 68
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REVISIONS
Date Description Author

st
06/18/2014 1 Release, SG format and updates RZ
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1.0 GENERAL INFORMATION

Throughout this manual you will see one or more of the following four (4)
messages in colored typeface. Please pay close attention to these messages, as
they are important for the safe and efficient operation of your new SERVAgroup
equipment.
WARNING: A WARNING message (in red) indicates a potential personal

hazard. Failure to heed these warnings could result in serious injury or
death to crewmembers using the unit or personnel at the well site.
CAUTION: A CAUTION message (in orange) indicates a potential hazard

to the equipment. Failure to heed these cautionary messages could
result in serious equipment damage.
IMPORTANT: An IMPORTANT message (in green) is a reminder about the

unit and its operation. Failure to heed these important messages could
reduce the efficiency of the unit or result in unnecessary activities such as
repairs or down time.
RECOMMENDATION: A RECOMMENDATION (in blue) points out facts

about the unit that are not required as part of the maintenance or
operation, but will greatly enhance the performance or service life of the
unit.
1.1 Safety Precautions

Follow all safety precautions when you operate a QPA1000 pump.
Failure to do so could result in equipment damage, serious bodily harm
or even death.
1. Wear Personal Protective Equipment (PPE). Review the PPE manual

for specification son hard hat, goggles, gloves, steel-toed shoes, etc.
2. Flush the pump to remove any additives or other harmful chemicals

that could cause bodily harm if in contact with skin or clothing.
3. Carefully bleed pressure from the fluid end. Isolate the pump from
pressure and vent the pump to the atmosphere.
4. Turn off the prime mover (engine or electric motor).
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Never place your hands in the fluid end, the area between the fluid end
and the power or the input flange when the prime mover is on. Serious
injury could result.
5. Disengage the prime mover from the pump (put the transmission in
neutral) or lock the electric motor to prevent accidental start-up.
6. File smooth (or replace) any parts that have sharp or jagged edges.
7. Use a remote-operated choke to build pressure in the QPA1000

pump.
Never use a fully closed valve to bu8ild pressure in a positive

displacement pump. Sudden overpressure could result, causing serious
damage and/or bodily harm.
8. Use care when lifting or moving pump parts. Many of the parts are
heavy enough to cause injury if improperly handled. Lift pump parts
with assistance from additional personnel, or a hoist or other lifting
device.
9. If you turn the pump input shaft with a tool such as a pry bar or pipe
wrench, remove the tool from the shaft immediately after use.
Do not start the pump if there is a tool attached to the driveshaft.

Serious damage and/or injury could result.
10. Before starting the pump, make sure all discharge valves are open
and all protective guards are in place.
11. Never weld on a pressure-containing part such as a fluid end,

discharge flange, etc. without prior approval of appropriate personnel
and SERVAgroup Engineering.
Always avoid flames when using flammable liquids to wash the pump
parts.
1.2 QPA1000 Pump Description

The QPA1000 is a reciprocating, positive displacement, horizontal single-acting,
quintuplex plunger pump rated at 1000 Brake Horsepower input maximum. It is
designed for severe duty well service applications such as acidizing, cementing,
fracturing, well killing, gravel packing, etc.
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The QPA1000 Pump consists of a power end, speed reducer assembly and a
fluid end assembly. The speed reducer can install on either the right hand or left
hand side of the pump in any one of 16 different input shaft locations to
accommodate a number of different pumping unit drive train configurations.
Two 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 variety of usage configurations, for pumping
various specific fluids and for service in a wide range of climates.
The weight of the pump will vary slightly, depending on plunger size and other
options but will not vary more than +/- 5% of the advertised weight.
You can use the QPA1000 pump to pump liquid medium into a well. The
QPA1000 pump is not rated for sour gas service such as hydrogen sulfide (H2S)
because it can make the iron brittle. This reduces the fluid suction and the ability
to sustain pressure.
QPA1000 pumps work well where ambient temperatures range from -30° C to
45° C. If the ambient temperature exceeds these limits, please contact the
SERVAgroup Engineering department.
1.2.1 Performance Data 1
Rated Maximum Brake Horsepower 1000 BHP (746 Kw)

Maximum Rod Load 100,000 LBF (45,359 kg)
Stroke Length 6” (152.4mm)
Gear Ratio 4.6:1
Length 50.25” (1276mm)
Width 52.93” (1344mm)
Height 23.88” (607mm)
Weight Dry (Approximate) 7,000 Lbs. (3175kg)
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1.2.2 Performance Data 2
Plunger Output Displacement at Pump Strokes per Minute/Pinion RPM

Diameter per REV 50/230 120/552 200/920 300/1380 450/2070
In. Gal./Rev. GPM PSI GPM PSI GPM PSI GPM PSI GPM PSI
mm Liter/Rev. (LPM) (MPa) (LPM) (MPa) (LPM) (MPa) (LPM) (MPa) (LPM) (MPa)
3 .92 47 15,000 110 14,003 183 8,402 275 5,601 413 3,734
76.2 3.5 (173) (103.4) (417) (96.6) (695) (57.9) (1042) (38.6) (1563) (25.8)
3½ 1.25 62 10,394 150 10,288 250 6,173 375 4,115 562 2,744
88.9 4.7 (237) (71.7) (568) (71.0) (947) (42.6) (1418) (28.4) (2128) (18.9)
4 1.63 82 7,958 197 7,877 327 4,726 490 3.151 735 2,100
101.6 6.2 (308) (54.9) (742) (54.3) (1235) (32.6) (1853) (21.7) (2780) (14.5)
4½ 2.07 103 6,288 248 6,224 413 3,734 620 2.489 929 1,660
114.3 7.8 (392) (43.4) (938) (42.9) (1563) (25.8) (2345) (17.2) (3518) (11.4)
Input Power
421(314) 1000(746) 1000(746) 1000(746) 1000(746)
BHP(Kw)
1.2.3 Tachometer Drive/Rate Meter Calibration Specifications
Fluid
Plunger
Diameter per Tachometer Drive Revolution per Tachometer Drive Revolution
Inches at 95% VE at 100% VE
(mm)
GPR BPR LPR GPR BPR LPR
3
.1047 .00249 .3961 .1102 .00262 .4170
(76.2)
3½
.1424 .00339 .5391 .1499 .00357 .5675
(88.9)
4
.1860 .00443 .7042 .1958 .00466 .7413
(101.6)
4½ .2355 .00561 .8912 .2479 .00590 .9382

(114.3)
VE - Volumetric Efficiency of pump
GPR - Gallons (US) per Revolution
BPR - Barrels (US) per Revolution
LPR - Liters per Revolution
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The volumetric efficiency and resulting displacement may vary slightly due
to operational factors, such as pump speed; supercharge conditions and
the specific gravity of the fluid in the pump.
1.2.4 Identification Plate
1.2.5 Pump Noise
The more horsepower and higher RPM, the more noise the pump
generates. The table that follows lists the 4 1/2” QPA1000 pump noise
on full rated work horsepower while using an Allison HT750
transmission. The table is for reference only. Your results may vary.
Background Noise
Transmission Noise at Noise at dB(A)
Pinion
Gear Power End Fluid End
Speed At Power At Fluid
Location dB(A) dB(A)
End End
1st 230 92.9 94.1 83.2 87.2
2nd 552 97.8 95.4 83.0 86.5
3rd 920 93.4 91.1 85.0 89.0
4th 1380 97.2 95.3 84.5 92.2
5th 2070 109.3 105.4 92.3 101.2
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1.3 Replacement Parts

SERVAgroup stocks an inventory of genuine “original equipment” replacement
parts for each of its pumps. In order to expedite a parts order and avoid any
delays, please provide the following information when you place an order.
1. The part number and description of each item ordered. (Refer to

drawings and parts lists in this document.)
2. The quantity of each part, kit or assembly ordered.
3. The model number and serial number of the pump (see identification
tags on the fluid and power ends.)
4. Your purchase order number.
5. Specify the method of shipment and complete shipping address,

complete billing address and telephone number for the destination of
the shipment.
1.4 Shipping and Storage

All pumps are shipped dry and must be flushed with diesel (or light) oil and filled
with the proper lubricant before operating (see section 2.0 Installation Details).
When shipping a pump by ocean cargo, crate the pump in a watertight container
and stow below deck to prevent salt water contamination.
New pumps are not prepared for long periods of storage and should be used as
soon as possible. To prepare a pump for storage after use, perform these steps.
1. Clean the fluid end and flush it with a good rust preventive and then
plug all fluid end discharge and suction openings.
2. Drain the oil from the power end and thoroughly clean and flush with
a good rust preventive that will not clog oil passages.
3. Remove the crankcase breather and plug all openings.
4. Coat the pinion extensions and pony rods with a heavy rust
preventive.
5. Store pump inside in a warm, dry location.
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Pumps that are idle for any appreciable period of time (two weeks or more) must have
the plungers and valves removed, coated with a light lubricant and reinstalled prior to
operating. The elastomeric plunger packing and valve inserts will stick to the matching
metal parts and suffer damage upon start-up if not disassembled and lubricated first.
SERVAgroup recommends use of a forklift and crane to move the pump. The pictures
that follow illustrate both methods.
Forklift
Crane
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2.0 INSTALLATION DETAILS

2.1 Pump Installation Highlights
Install your QPA1000 well service pump properly to obtain long life and trouble
free service. Pay particular attention to the following.
2.1.1 Power Source
To avoid overpowering the pump, the prime mover (usually a 2100

RPM diesel engine) should be rated at no more than 725 BHP
intermittent service.
2.1.2 Drivetrain
The drivetrain that connects the pump to the engine should include a
transmission (5 speed or more) and a mechanical driveline with
universal joints and a slip joint to fully utilize the wide range of pressure
and flow capabilities.
The mechanical driveline should have a “Diesel Engine Use” torque

rating of approximately 1250 to 1700 ft. lbs. (6500 to 8900 ft. lbs. Short
Duration) and no less than 1” slip capacity.
Do not exceed the manufacturer’s recommendations for maximum

installed angle, maximum RPM, etc.
 A power shift transmission with integral torque converter and

automatic lock-up clutch provides the most trouble-free shifting
under pressure. If you must use a transmission with a manual
clutch, exercise extreme caution when clutching and shifting to
avoid introducing severe shock loads to the pump’s input shaft.
 If you use a transmission with a high gear or overdrive ratio greater

than 1.0:1, you must block out the overdrive gear range to avoid
running the pump too fast.
 If you use a transmission with a torque convertor and/or a low gear

ratio of 5.0:1 or lower, exercise extreme caution to avoid over-
pressuring the pump when operating in low gear or converter
mode.
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2.1.3 Power End Mounting
Securely bolt all four (4) power end mounting hold locations to a skid or
vehicle. (Refer to pump installation drawings for mounting hold
locations.)
2.1.4 Power End Lubrication
QPA1000 pumps are shipped dry, do not include an integral oil pump,
and are designed for a pressure lubricated dry sump system. For
proper lubrication there must be an auxiliary oil reservoir and engine
driven oil pump used with the QPA1000. Additional information about
the power end lube system and oils is in section 3.0 Power End Lube
System Requirements.
2.1.5 Plunger Lubrication
The QPA1000 well service plunger pump requires a force fed oil
plunger lube system. The unit is internally and externally plumbed so
that the correct oil source provided by the customer will supply oil to all
appropriate surfaces.
2.1.6 Super-charging System
The QPA1000 requires a centrifugal slurry pump super-charging

system.
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2.2 Installation Detail Drawing
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2.3 Start-up and Break-in Procedure

Each pump must undergo a brief but thorough start-up and break-in procedure to
verify the field worthiness of the pumping system and allow a gradual “breaking
in” of various mating parts in the pump itself. SERVAgroup recommends
adhering to the following guidelines to insure maximum service from the plunger
pump and minimize potential start-up problems.
2.3.1 Inspection Procedure

(prior to starting the engine, verify the following)
1. All masking tape, rust preventive and other material used for shipping
is absent from moving parts such as plungers, pinion shaft, etc.
2. The bolts attaching the plunger pump to the skid or truck frame are
secure.
3. The connection from the driveline to the plunger pump’s input shaft is
secure and adequate slip is present in the driveline’s slip joint.
4. The power end lube oil reservoir has the proper type of gear oil
added after flushing and draining.
5. The plunger lube oil reservoir has the proper type of rock drill oil
added after flushing and draining.
6. Piping connections on the super-charge piping system are tight after

completely flushing the system.
7. The power end lube system start-up adjustments and plunger lube
system start-up adjustments are complete.
8. The suction pulsation dampener is properly pre-charged.
9. There is an adequate supply of cool clean water for testing

connected to the primary suction piping.
10. The connection from the plunger pump’s discharge piping to the
water reservoir is secure. All connections are tight and all valves are
open.
Start the super-charge pump and flush all air from the system. Follow the engine
manufacturer’s recommendations for engine start-up and warm-up.
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2.3.2 Warm-up Procedure (prior to rotating the plunger pump)
1. Operate the engine at idle and the transmission in neutral and check:
 the power end lube pump vacuum reading and
 the power end lube oil pressure and 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 with the lube pump vacuum reading at
or below 10” Hg as necessary to warm and thin the power end lube
oil.
3. Do not rotate the plunger pump until you achieve full engine RPM
without exceeding 1V Hg at the lube pump suction inlet or until the
power end lube oil temperature reaches at least 60° F.
2.3.3 Plunger Pump Valve Seating Procedure
To protect the fluid cylinder from washing before sustained pumping,

pressure up and fully seat the tapered valve seats to create a positive
fluid seal.
1. Adjust the test choke for high pressure/low pump RPM.
Set the over pressure shutdown to prevent over pressuring during this
operation.
Shift the transmission to 1st gear and slowly increase the throttle setting
to achieve 85% of the pump’s maximum rated rod load for 2 - 3 minutes
or, until you hear a series of popping noises. The popping noises
indicate that the seats have properly set in the taper. The desired
pressure for each plunger size is in the following table.
Plunger Diameter (In.) 85% Rated Pressure

3 12,030 PSI
3½ 8,840 PSI
4 6,675 PSI
4½ 5,345 PSI
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2. During this portion of the start-up 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, super-charge pressure, etc. for future reference.
3. Return the engine to idle and the transmission to neutral and

physically inspect the plunger pump before proceeding.
2.3.4 Break-In Procedure
1. Adjust the test choke, engine, and transmission to obtain

approximately 35% rated rod load, 35% rated pump RPM, and 42%
rated horsepower. These settings should be approximately as
follows:
Plunger Diameter
Pump RPM GPM/BPM PSI BHP
(In)
3 143 79/1.88 4,955 250
3½ 143 107/2.55 3,640 250
4 143 140/3.33 2,785 250
4½ 143 177/4.21 2,200 250
2. Run the plunger pump at the selected setting for one hour. During
this time, closely observe the plunger pump for any unusual noise,
vibration, fluid leaks or oil leaks. Record all pertinent information such
as elapsed time, ambient temperature, power end lube oil
temperature, power end oil pressure, super-charge pressure, etc. for
future reference.

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4. Adjust the test choke, engine and transmission to obtain

approximately 40% rated rod load, 50% rated pump RPM and 75%
rated horsepower. The settings should be approximately the same as
shown in the following table.
Plunger Diameter
(In.)
3 225 124/2.95 5,660 455
3½ 225 169/4.02 4,160 455
4 225 221/5.26 3,185 455
4½ 225 279/6.64 2,515 455
5. Run the plunger pump at this setting for one hour. Closely observe
the plunger pump for any unusual noise, vibration, fluid leaks or 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.
6. Return the engine to idle and transmission to neutral and physically

inspect the plunger pump before proceeding.
7. Adjust the test choke, the engine and the transmission to obtain
approximately 22% rated rod load, 100% rated pump RPM and 83%
rated horsepower. The setting should be approximately as follows.
Plunger Diameter
(In.)
3 450 248/5.90 3,115 500
3½ 450 338/8.05 2,290 500
4 450 441/10.50 1,750 500
4½ 450 558/13.29 1,385 500
8. Run the pump at this setting for 30 minutes. Closely observe the
plunger pump for any unusual noise, vibration, fluid leaks or oil leaks.
Record all pertinent information such as elapsed time; ambient
temperature; power end lube oil temperature, power end lube oil
pressure, super-charge pressure, etc. for future reference.
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10. Adjust the test choke, engine, and transmission to obtain

approximately 100% rated rod load, 12.5% rated pump RPM, and
47% rated horsepower. These settings should be approximately as
follows:
Plunger Diameter
Pump RPM GPM/BPM PSI HP
(In.)
3 57 31/0.74 14,155 285
3½ 57 3/1.02 10,400 285
4 57 6/1.33 7,960 285
4½ 57 71/1.69 6,290 285
11. Run the pump at this setting for 30 minutes. During this time, closely
observe the plunger pump for any unusual noise, vibration, fluid leaks
or oil leaks. Record all pertinent information such as elapsed time;
ambient temperature; power end lube oil temperature, power end
lube oil pressure, super-charge pressure, etc. for future reference.
12. Return the engine to idle, the transmission to neutral, and shut off the
engine.
13. Visually inspect the power end for oil leaks around the plunger seals,
pinion seal, lubrication hoses, lube drain hoses, covers, etc. Visually
inspect the fluid end for fluid leaks around the suction covers,
discharge covers, discharge flanges, stuffing boxes, and suction
manifold. Visually inspect the plungers for any signs of heating or
scoring. Remove the power end lube system magnet and inspect for
any unusually large particles of metal. Change the lube oil filters.
Pressure is limited to 15,000 PSI due to discharge flange and plunger

configuration. For higher pressure, contact the SERVAgroup Engineering
department.
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3.0 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 QPA1000 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 an engine driven lube pump
to deliver maximum lube oil volume at high engine speeds regardless of slow pump
speeds.
The powered well service unit must have power end lube system components that are
compatible with the specific engine, transmission, etc. installed on the unit. A properly
designed power end lube system has the specifications listed in the sections which
follow..
QPA1000 PUMP
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3.1 Oil Reservoir

 50 gallon minimum capacity
 2” minimum suction outlet, located as deep as possible
 3” minimum return fitting for back drain
 1” minimum return fitting for relief valve
 Dipstick or sight glass to indicate oil level in the reservoir
 Serviceable magnet located near the 3” return port (highly

recommended)
 40 micron 25CRM minimum breather filler cap with a built-in

strainer to prevent debris from entering the reservoir
 Located as close to the plunger pump as possible, preferably

directly underneath and below the lowest drain port in the plunger
pump
3.2 Lube Pump

 Pump is a gear type pump rated at 30 GPM minimum at its installed
maximum RPM.
 Inlet and outlet ports are as large as possible (11/2” inlet and 3/4”
outlet preferred). If the gear pump suction inlet port is less than
1 1/2”, use a swage connection on the suction port to maintain
a 2” suction line as close as possible to the gear pump.
 Liquid filled vacuum gauge (0 to 30” Hg) is installed as close to the
gear pump suction port as possible in order to monitor the suction
flow conditions, especially during cold startup in cold climates.
 The gear pump may be coupled directly to an accessory drive

location on the engine or to the transmission with a pump-mount
power take-off (PTO). The transmission PTO mount usually offers
the advantage of a lower mounting and improved suction
conditions.
In either case, the lube pump mounting must be a direct coupled

positive drive arrangement that operates at engine speed whenever the
plunger pump’s prime mover is running.
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3.3 Lube System Pressure Lines and Oil Filter

 Pressure lines are 1” inner diameter minimum in order to maintain a
flow velocity of 10 to 12 ft. per second maximum.
 Pressure lines are wire reinforced with a minimum working

pressure of 800 PSI.
 Oil filter is rated at 50 GPM/200 PSI minimum, has a built-in 15 to

25 PSI relief valve and, 25 to 33 micron elements.
 Liquid filled 0 to 200 PSI oil pressure gauge is 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 consoles.)
 When you connect the oil inlet, you must connect the three inlets to
the lube oil pipe. (See the drawings on the next page.)
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Figure 1 ‐ Oil Inlet Connection
Figure 2 ‐ Lube Assembly, Power End
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3.4 Lube System Suction Lines and Oil Filter

 Must be 2” inner diameter minimum throughout so the suction
velocity never exceeds 2 to 3 ft. per second.
 Must include a suction strainer with 2” minimum port size, 40 to 100

mesh (400-150 micron) wire cloth, 3002 inches minimum element
area, 3 to 5 PSI (6 to 10 Hg) built-in bypass and rated at 50 GPM
minimum flow rate.
An in-line canister type strainer makes cleaning easier during routine

maintenance.
 If the lube pump is located above the fluid level in the reservoir, you
can use a 1 1/2” minimum swing type check valve in the suction line.
 The suction line should be as short as possible, free from excessive

bends and wire reinforced to prevent collapsing.
If the suction line is longer than 10 feet, compensate for the resulting
suction losses by increasing the line size beyond the minimum 2” inner
diameter.
3.5 Lube System Relief Valve and Relief Return Line

 The system relief valve should be a 3/4” 20 to 25 GPM 60 PSI
minimum and 200 PSI maximum, adjustable non-chattering type
relief valve.
 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.
 The relief return line should be 3/4” inner diameter minimum, wire
reinforced, rated at 800 PSI minimum operating pressure and
should return directly to the reservoir.
3.6 Lube Drain Lines (from Plunger Pump to Reservoir)

The QPA1000 pump is equipped with a 2” NPT drain port in the speed reducer
(gearbox) housing and a 3” NPT drain port in the bottom of the power end
housing.
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 The drain lines should never be smaller than the drain port in the
power end speed reducer and should be as short as possible.
 Keep the drain lines free of excessive bends and kinks so they can
flow continuously downhill to the reservoir. If necessary, you can
connect the 2” drain line from the speed reducer into a common 3”
drain line with a ‘t-joint’ and return it to the reservoir. You should
always use the lowest 2” NPT drain port in the speed reducer for
the drain line in order to prevent the speed reducer from
accumulating excess oil.
 Install a 0° to 250° F oil temperature gauge in the primary drain line

such that its sensor is submerged in the return oil from the plunger
pump.
The temperature gauge should be located in a place easily accessible

for viewing. An auxiliary oil temperature gauge is highly recommended
for units with a remote control console.
3.7 Optional Lube System Equipment

 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/250PSI minimum, and should have 3/4” minimum
inlet and outlet connections. If the well service unit will be subjected to
periods of cold weather, the oil cooler must be plumbed in a manner
that will allow the oil to bypass the cooler when cold ambient conditions
occur.
 In extremely cold ambient conditions, the use of either an electric
sump heater or a “tube and shell” heat exchanger may be required
to prevent 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 electric 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° F over 8 to 12 hours. The sump heater
must be thermostat controlled to prevent overheating the oil.
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When using a “tube and shell” type heat exchanger for lube oil heating
with engine jacket water, the heat exchanger should be rated at 50
GPM/250PSI 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° F.
Upon request, SERVAgroup can provide lube system components that

meet or exceed the specifications noted herein. Please contact the
SERVAgroup Engineering Department for any further information
pertaining to your specific pump lubrication requirements.
3.8 Recommended Power End Lube Oils

The proper grade of gear oil for adequate power end lubrication in various
climates is very important to obtain long life and trouble-free service. In all cases,
select gear oil that contains an “extreme pressure” (EP) additive, that meets or
exceeds U.S. Mil. Spec. Mil-L-2105B, and has a Timken Test rating no lower
than 45 lbs. Both automotive and industrial gear oils are acceptable lube oils for
various climates and ambient conditions, provided they meet these
specifications.
3.8.1 General Service Lube Oils
These oils are generally classified as ISO 320 (SAE 90) automotive
grade, recommended where ambient temperatures range from 20° F to
90° F. These oils have a pour point of approximately 0° F and a
viscosity rating of 85 SUS or more at 210° F. The plunger pump’s oil
temperature must not exceed 180° F when using one of these oils.
3.8.2 Extreme Cold Weather Lube Oils
Classification for these oils is generally ISO 150 (SAE 80) automotive
grade or AGMA #3EP industrial grade, recommended where ambient
temperatures range from -25° F to 70° F. These oils have a pour point
of approximately -25° F and a viscosity rating of 55 SUS at 210° F. The
plunger pump's oil temperature must not exceed 145° F when using
one of these oils.
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3.8.3 Extreme Hot Weather Lube Oils
Classification for these oils is generally ISO 460 (SAE 140) automotive
grade or AGMA #7 EP industrial grade, recommended where ambient
temperatures range from 35° F to 110° F. These oils have a pour point
of approximately 20°F and a viscosity rating of 140 SUS at 210° F. The
plunger pump's oil temperature must not exceed 200° F when using
one of these oils.
3.8.4 Power End Lube System Operation Specifications
Power end lube system reading will vary considerably due to the
extreme viscosity changes in the gear oil as it warms and thins from a
cold startup until it reaches full operating temperature. For example,
ISO 320 (SAE 90) wt. gear oil is very viscous at room temperature,
about 200 mPa-s at 90° F, and creates high system pressures.
When the temperature rises it becomes much less viscous, about

35mPa-s at 160° F, and creates lower system pressure. This makes it
difficult to establish a firm set of system readings that would be highly
accurate for every system.
Any sudden vacuum, pressure or temperature deviation from normal,

especially any unusual noise, vibration or smoke indicates the need to
cease pumping operation and investigate the problem before power end
damage occurs.
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Normally, if the pump is working at full horsepower and full torque the system
readings cannot exceed the temperatures and pressure measurements listed in
the following table.
Maximum/Minimum/Optimum Measurement Value

Maximum Acceptable Vacuum Reading at Lube Pump Suction
10" Hg
Inlet Any Time During Operation
Maximum Oil Pressure at Cold Startup and Full Engine RPM 175 PSI
Maximum Oil Temperature at Any Time:
ISO 150 (SAE 80) Gear Fluid 145° F
ISO 220 (SAE 75W 90) Gear Fluid 160° F
Best Oil Pressure at Stabilized Operating Temperature and Full
70-110 PSI
Engine RPM
Minimum Acceptable Oil Pressure at Any Time While Operating
40 PSI
at Stabilized Operating Temperature
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Figure 3 ‐ ISO Grade Fluid Chart
Oil viscosity should not exceed 7000 SSU at cold startup and must be between 1500 and
200 while operating, regardless of the type of ISO grade fluid used.
NOTE: Reservoir heaters (to preheat fluid) may be required in order to meet these operating conditions.

INLET OR SUMP GAUGE FLUIDS FOR MEDIUM TO
FLUID TEMP HIGH AMBIENT
TEMPERATURES
°F °C
200 93
ISO Grade Fluid
190 88 FLUIDS FOR LOW TO
180 82 MEDIUM AMBIENT Temperature Legend
TEMPERATURES
170 77
160 71
LINE START – minimum no
150 66 load start-up temperature
140 60
130 54 DIAMOND – minimum
operating temperature – do
120 49 not load pump until this temp
110 43 is reached
100 38
ARROW – recommended
90 32 peak operating temperature
80 27 for longest life
70 21 ISO 460
DOT – maximum allowable
60 16
stabilized temperature during
50 10 ISO 320 normal operation
40 4
30 ‐1 ISO 220

ISO 150

Fluids used must contain anti-foaming, non-corrosive and rust inhibiting additives.

FAILURE TO FOLLOW LUBRICATION REQUIREMENTS VOIDS THE WARRANTY
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4.0 PLUNGER LUBE SYSTEM PUMP REQUIREMENTS

The QPA1000 pump design calls for packing lubrication with oil rather than grease. You
can expect exceptionally long packing life if proper lubrication is supplied to the plunger
packing lube port above each stuffing box. Achieve ample plunger and packing
lubrication 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
meets the following specifications.
4.1 Oil Reservoir

 approximately 5-gallon capacity
 equipped with a sight glass or dipstick
 equipped with a breather/filler cap that has a built-in strainer to

prevent trash from entering the reservoir
4.2 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.
 cracking pressure of 32 PSI
 equipped with a pressure gauge between the relief valve and

lubricant pump
 return line connected from the relief valve to the oil reservoir so that
vented oil will return to the oil reservoir
4.3 Flow Control Needle Valves

 1
/4" needle valve which can be locked at any given setting after
adjustment
 installed in each lubricant flow line that leads to the individual

packing lube ports in the plunger pump fluid cylinder
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4.4 High Pressure Check Valves

 rated at or above the well service plunger pump's maximum
pressure rating
 installed in the packing lube port so that the direction of flow is into
the fluid cylinder
4.5 Recommended Plunger Lube Oils
Select the proper grade of plunger lube oil for adequate lubrication in various
climates to obtain long life and trouble-free service. In all cases, “rock drill” oil
should contain an "extreme pressure" (EP) additive, have a film strength of
300,000 PSI or more and a relatively low coefficient of static friction.
Choosing the right plunger lubricant is critical for good packing and plunger life
for all styles of packing. Failure to provide adequate or appropriate lube will
cause the packing to fail and damage the mating components.
SERVAgroup recommends using rock bit or way oil that meets the following
specifications:
Plunger Lube Oil Specifications
ISO Grade 32 68
CPS No. 232500 232511
AGMA Grade --- 2
API Gravity 21.4 25.6
Viscosity, Kinematics
cSt at 40° C 30.4 64.6
cSt at 100° C 4.9 7.3
Viscosity, Saybolt
SUS at 100° C 158 338
SUS at 210° C 42.7 50.8
Viscosity Index 74 61
Flash Point 170° C (338° F) 200° C (389° F)
Lubricants that fail to meet these specifications, and especially “used crankcase
oils” are unacceptable.
Start-up is a critical time for plunger packing. Lubrication should flow freely to the
plunger prior to stroking the pump. Although conditions vary, twenty (20) drops
per minute lube oil rate is the generally recommended rate.
Stroking dry plungers can cause the header ring and packing to tear and
fail.
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5.0 TROUBLESHOOTING GUIDE

Symptom Probable
C
 Extremely cold ambient
Abnormally high vacuum at power end
temperature/dangerously high oil viscosity
lube pump suction inlet (may or may not
 Clogged lube system suction strainer
be accompanied by abnormally low oil
 Kinked or collapsed lube system suction hose
pressure)
 Clogged oil reservoir breather
 Erroneous gauge reading
 Leak in lube pump suction piping which allows
air to be drawn into the system
Abnormally low power end lube oil  Worn or damaged lube pump
pressure with normal to low vacuum  Leak in lube pump pressure piping
reading at lube pump suction (may or may  Low oil level in reservoir
not be accompanied by high oil  Clogged oil filter element
temperature)  Faulty lube system relief valve
 Extremely hot lube oil temperature/dangerously
low oil viscosity.
 Extremely warm ambient
temperature/dangerously low oil
viscosity/incorrect grade of gear oil
Abnormally high power end lube oil  Gear oil contaminated with water, trash or
temperature (may or may not be air bubbles
accompanied by low oil pressure)  Plunger pump has been operated continuously
for too long a period of time at or near its
maximum horsepower or torque rating.
 Heat exchanger or oil cooler malfunction
 Extremely cold ambient
temperature/high oil viscosity
 Damaged seal surface on mating part
Leaking power end oil seals.
 Clogged oil breather/high crankcase pressure
 Worn or damaged seal
 Contaminated lube oil
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Symptom Probable
C
 Seal installed improperly
 Seal cut or pinched on installation
 Mating seal surface not cleaned properly prior to
Leaking fluid end seals
seal installation.
 Damaged or corroded mating seal surface.
 Sealing part not properly tightened.
 Packing nut not tightened properly.
 Worn or damaged packing.
 Packing installed improperly.
Plunger and/or packing fluid leak  Mating seal surface not cleaned properly
prior to packing installation.
 Damaged or corroded mating seal surface.
 Fluid being pumped is incompatible with the
style packing being used.
 Air entering supercharge system through loose,
worn or damaged connections.
 Air entering supercharge system through
leaking charge pump seals.
 Fluid being pumped contains gas or vapor.
Fluid knock or hammer
 Insufficient supercharge flow or pressure.
 Valve cocked open/broken valve spring or valve
stop.
 Worn or damaged valve, valve insert, or valve
seat.
 Improperly charged or ineffective suction
pulsation dampener.
 Worn or damaged valve, assembly.
 Insufficient supercharge flow or pressure.
Low discharge pressure/rough  Air, gas or vapor in fluid being pumped.
running pump  Improperly charged or ineffective suction
pulsation dampener.
 Two or more plunger pumps being supercharged
by a common charge pump and being allowed to get
“in phase” with each other.
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6.0 ROUTINE MAINTENANCE

Obtain maximum service and trouble-free operation from the QPA1000 well service
plunger pump by establishing a thorough preventive maintenance program, provided in
the following checklists.
Table 1 ‐ First 100 Hours of New Pump Operation
Completed
Action What and Why 
By (Initials)
Power end lube oil filters to prevent filter bypass (suggest every
Change
25 hours or more often if needed)
Power end lube oil suction strainer after first 50 and 100 hours of
Clean
operation to prevent filter bypass/pressure loss.
Change Power end lube oil after first 100 hours of operation.
Clean Lube oil reservoir after first 100 hours of operation.
Table 2 ‐ Daily
Completed
By (Initials)
Oil level in the power end lube oil reservoir. Add if necessary.
Oil level in the plunger lube oil reservoir. Add if necessary.
Plunger pump; examine for oil and/or fluid leaks.
Check
Power end lube oil system; examine for leaks.
Plunger lube system; examine for leaks.
Supercharge piping; examine for leaks.
Table 3 ‐ Weekly
Completed
By (Initials)
All items on Daily Preventive Maintenance list.
All valves, inserts, valve seals and springs.
Check
Discharge and suction cover seals.
Suction pulsation dampener for correct pre-charge.

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Table 4 ‐ Monthly (or Every 100 Hours)

Completed
By (Initials)
Check All items on Daily, Weekly and Monthly Maintenance lists.
Change Power end lube oil; refill with proper grade of gear oil for upcoming
ambient conditions.
Clean Power end lube oil suction strainer.
Remove Plungers and packing assembly components; replace all packing
pressure rings and header rings.
Plunger pump oil breather and power end lube oil reservoir
Clean
breather.

Table 5 ‐ Quarterly (or Every 250 Hours)
Completed
By (Initials)
All items on Daily and Weekly Maintenance lists.
Fluid cylinder mounting bolts; ensure they are tight.
Plunger pump mounting bolts; ensure they are tight.
Check Power end lube oil filters; replace if necessary.
Supplies needed for routine maintenance (O-rings, fluid seals,
valves, valve inserts, valve seals, valve springs, packing, oil seals,
filter elements, etc.)
Table 6 ‐ Yearly (or as required)
Completed
By (Initials)
Worn plungers and packing brass.
Worn or corroded valve covers, suction valve
stops, packing nuts, discharge flanges, pump
Replace tools, etc.
All discharge flange seals and suction manifold
seals.
Any defective gauges and/or instruments.
Inspect Power end lube oil pump; rebuild if necessary.
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It is difficult to assess wear and tear on a pump based solely on the hours operated due
to the variations in duty cycle and types of service. You may need to replace roller
bearings, rod bearings and gearing after approximately 3000 hours of use. These
components generally exhibit signs of extensive wear by spalling (or flaking), which
causes pitting or scoring on the working surfaces. A small amount of spalling is tolerable
on gear faces but any spalling on a bearing surface indicates replacement is needed as
soon as possible.
Although replacement of these major components is relatively expensive, failure of a

main bearing can quite often lead to serious crankshaft and/or power frame damage.
Close observation of the lube oil filters during routine maintenance generally reveals the
condition of roller bearings, gears and journal bearings. SERVAgroup recommends
pulling the inspection covers and observing the condition of the bearings and gears
every 500 hours.
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7.0 FLUID END REPAIR PROCEDURES
7.1 Remove Valves and Seats

1. Use the 2” hex cover wrench and a 10 lb. hammer to remove the
suction covers and discharge covers from the fluid cylinder.
2. Turn the suction valve stops approximately 90 degrees and then

remove them from the fluid cylinder, along with the valve springs
underneath them.
3. Use a magnetic valve removal tool to cock each suction valve to one
side in order to drain any fluid. Remove the valve from the fluid
cylinder. Follow the valve manufacturer’s recommendation for
removing the insert from the valve.
4. Remove the discharge valve springs and discharge valves from the
fluid cylinder.
5. Use a hydraulic seat puller assembly to remove each of the

discharge valve seats and suction valve seats.
6. Thoroughly clean and lightly hand polish the tapered valve seat bore
in the fluid with a 220 to 240-grit emery cloth prior to installing new
valve seats.
7. Always install a new O-ring seal when reinstalling a valve seat. Do

not use any type of grease, sealant, etc. The valve seat must be
dry. Install the valve seat by hand; install the valve in the valve seat
and use a heavy steel bar to hammer the valve seat into the taper.
8. Never use one manufacturer’s valve with another manufacturer’s

valve seat. Likewise, never use one manufacturer’s valve insert with
another manufacturer’s valve.
9. When you reinstall the suction valve stop, make sure it is

perpendicular to the plunger and securely seated in the groove in the
cylinder.
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10. Reinstall the discharge and suction covers as follows.
 Remove the seals from the covers.

 Thoroughly clean the covers.
 Install new seals in the same direction that the old ones came off.
 Thoroughly clean each cover bore in the fluid cylinder.
 Lightly hand polish each cover bore with a 220 to 240-grit emery
cloth.
 Reinstall the covers.
11. Lightly coat the threaded suction and discharge covers with oil or
very light grease and tighten them securely with the 2” hex cover
wrench and a 10 lb. hammer.
7.2 Change Plungers and Packing

1. Remove the plunger lube fitting from each packing nut.
2. Use the packing nut tool to loosen each of the packing nuts at least
one full turn.
3. Remove the suction covers as directed in 7.1 Remove Valves and

Seats.
4. Use the plunger wrench to unscrew the plunger from the crosshead
and pull it out of the fluid cylinder through the suction cover bore.
Take care to prevent contaminants from entering the power end section
after removing the plunger.
5. Secure the seal ring with the seal ring retainer or other suitable tool
and completely remove each packing nut from the packing gland
thread bore. Label each packing nut upon removal to ensure
installation back into the same bore.
The seal ring must remain in the cylinder when removing the packing
nut.
6. Remove the seal ring from the cylinder.
7. Inspect each plunger for wear, scoring and corrosion on the hard
surface area and for damage to the face that mates with the
crosshead.
8. Inspect each ring of packing brass for excessive wear and scoring.
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9. Blow air through the lube port on each packing nut to ensure that the
lube passage is unobstructed.
10. Thoroughly clean each packing bore inside the packing nut and
inside the fluid cylinder. Then, lightly hand polish with 220 to 240 grit
emery cloth prior to reinstalling the packing.
11. Reinstall the packing assembly one piece at a time, using new
packing, header rings and pressure rings. Coat each ring with light oil
and take care to avoid damage to the internal and external sealing
lips of each packing ring. (Refer to 7.1 Remove Valves and Seats.)
12. Replace the O-rings and back-up rings in the seal rings and dress the
seal ring seal areas in the fluid cylinder and in the packing nut with
220 to 240 grit emery cloth. Reinstall the seal ring as illustrated in the
Packing Assembly diagram.
13. Reinstall each packing nut into the appropriate cylinder and screw it
all the way in until tight. After it is tight, unscrew it one or two turns.
14. Coat the hard surface area of each plunger with light oil and insert
the plunger into the packing.
15. Use an aluminum bar and 10 lb. hammer to bump the plunger into
the packing while holding it as straight as possible with the packing
bore center line. Continue bumping the plunger through the packing
until the threaded bore approaches the crosshead stud. For solid
studded plungers, continue until the stud nears the crosshead
threads.
16. Carefully align the plunger and crosshead and gently bump the
plunger up against the crosshead.
17. Tighten the plunger to the crosshead with the plunger wrench to
achieve torque (250 – 350 ft. lbs.).
18. Use the packing nut wrench to tighten each packing nut as tight as
possible.
The packing nut will need retightening only once after reassembling and
running the pump under pressure for a few revolutions. After that, the
packing is completely self-adjusting.
19. Reinstall the packing lube fitting into the packing nut.
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20. Reinstall the suction covers as outlined in 7.1 Remove Valves and
Seats.
7.3 Remove Discharge Flanges

1. Use a 1 5/8” wrench to remove the five (5) nuts from each of the two
(2) discharge flanges.
2. Remove each discharge flange from the fluid cylinder.
 Remove the fluid seals from the inlet and outlet sides of each
discharge flange.
 Inspect each discharge flange for internal erosion and/or corrosion.
 Inspect the discharge flange threads for wear or damage.
 Thoroughly clean the discharge flange seal surfaces
 Lightly polish the discharge flange seal surfaces with a 220 to

240 grit emery cloth prior to reinstallation.
3. Inspect the fluid cylinder discharge flange bores for erosion and/or
corrosion. Thoroughly clean and lightly polish each bore with a 220 to
240 grit emery cloth prior to reinstalling the discharge flanges.
4. Reinstall each discharge flange, using new fluid seals and a coating
of light oil. Be careful to avoid damaging the seal on the inlet side of
the flange.
5. Reinstall the five (5) nuts on each flange and evenly tighten them to
the proper torque. (Refer to the torque table in 8.0 Torque Table.)
7.4 Remove the Suction Manifold

1. Use a 1 1/8" wrench to remove the twenty (20) 3/4" cap screws that
secure the suction manifold to the fluid cylinder and then drop the
suction manifold away from the fluid cylinder.
2. Inspect the suction manifold for internal erosion/corrosion Remove

the five (5) suction manifold O-ring seals and inspect the seal
grooves in the manifold for erosion/corrosion.
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3. Inspect the face and outer diameter of the pipe at each end of the
manifold for erosion/corrosion.
The manifold incorporates a Victaulic “ES” type connection at each end

which accepts either a Victaulic “End Seal Cut Groove” gasket or
“Standard Cut Groove” gasket. The condition of the pipe face at each
end of the manifold is only important for sealing purposes when the
“End Seal (ES)” gasket is used.
4. Inspect the bottom face of the fluid cylinder for erosion/corrosion.
5. Thoroughly clean and lightly polish the bottom face of the fluid
cylinder with a 220 to 240 grit emery cloth prior to reinstalling the
suction manifold.
6. Using new O-ring seals, reinstall the suction manifold. Reinstall the
twenty (20) 3/4" cap screws and evenly tighten them to the proper
torque (see 8.0 Torque Table in this manual).
7.5 Remove the Fluid End

1. Disconnect the plunger from the crosshead using the plunger wrench
as outlined in 7.2 Change Plungers and Packing.
2. Disconnect the plunger lube hoses and any discharge piping

connections and suction piping connections necessary for fluid end
removal.
3. Remove the four (4) 1” bolts and the four (4) 13/8” bolts (using a hand
wrench, not an impact wrench) which secure the fluid cylinder to the
power end. Remove the fluid cylinder from the power end.
The fluid cylinder is only secured by these eight (8) bolts so be sure to
provide support before removing the bolts.
4. Examine the mating surfaces of the fluid cylinder and nose plate for
signs of damage. Examine mounting bolt threads for signs of
damage. Repair or replace as necessary.
5. Clean and lubricate the fluid cylinder mounting bolt threads and hand
tighten the eight (8) bolts. Use a torque wrench to tighten the four (4)
1” bolts to 500 ft.-lbs., and the four (4) 1 3/8” bolts to 1300 ft.-lbs.
6. Reconnect all hose and piping connections and tighten plunger to

crosshead to torque of 250 to 350 ft.-lbs.
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7.6 Power End Repair Procedures

Due to the complexity of the task and the need for special tools and training,
SERVAgroup does not recommend complete disassembly of the QPA1000
power end or speed reducer in the field. If extensive power end repairs are
required, return the pump to a SERVAgroup facility where expert service can be
obtained on an expedited or emergency basis if needed.
When field repairs are required, they should be performed in a clean, well
equipped shop by a trained well service technician who follows these
procedures.
7.6.1 Remove and Disassemble the Speed Reducer
You can remove the QPA1000 speed reducer assembly from the power
end without disassembling the speed reducer, with a 1 1/16” wrench.
Use the wrench for the eight (8) 7/8” hex nuts that secure the speed
reducer to the power end.
SERVAgroup recommends removing the speed reducer intact if

possible. If speed reducer internal repairs are required, follow these
steps to inspect or replace the bull gear, pinion shaft or roller bearings.
1. Remove the unit's mechanical driveline from the pump's input shaft.
2. Disconnect the lubrication hoses from the speed reducer and remove
the speed reducer as a complete assembly from the power end. Lay
the speed reducer down on its mounting flange face with the input
shaft facing up.
3. Use a 11/2” wrench to remove the 1” cap screw that secures the
splined companion flange to the input shaft. Remove the companion
flange and inspect it for wear.
4. Use a 3/4” wrench to remove the eight (8) 1/2” cap screws that hold
the pinion seal retainer to the speed reducer housing.
5. Remove the pinion seal retainer and shims from the speed reducer.
6. Remove the oil seal from the retainer and scrape all old silicone
sealer from the retainer.
7. Use a punch and hammer to drive the five (5) 3/4” dowel pins from the
outer flange of the speed reducer housing.
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Volume 1 of 1
8. Use a 3/4” wrench to remove the twenty-four (24) 1/2” cap screws,
nuts and washers that secure the speed reducer cover plate to the
housing.
9. Remove the eight (8) 1/2” cap screws that secure the bearing cover to
the speed reducer. Remove the bearing cover and shims and lift the
cover plate away.
10. Scrape all old silicone sealer from the speed reducer cover and from
the flange on the housing. Use a brass punch and hammer to drive
both bearing cups (outer races) from the cover plate and inspect
them for wear or damage.
11. Remove the bull gear from the pump and inspect the gear teeth and
both tapered roller bearing cones for wear and damage.
12. Remove the pinion shaft from the speed reducer and inspect both
tapered roller bearing cones for wear and damage.
If you need to remove the bearing cones from the shaft, carefully heat
them with an acetylene torch until they easily slip off. Avoid
overheating the shaft itself. Inspect the shaft for wear and damage to
the gear teeth, seal surface, and bearing journals.
13. Reassemble the speed reducer in the reverse order of the

disassembly.
14. Install new tapered roller bearing cones on the pinion shaft or bull
gear by pressing them on or by heating the cone assembly with one
of these methods.
• a temperature controlled heating plate
• a hot oil bath unit
• a hot air cabinet or induction heating unit
These methods can safely heat the bearings for installation but the
temperature must not exceed 250° F (121° C).
Service Manual
Volume 1 of 1
15. Install new tapered roller bearing cups in the housing by tapping
them into the housing with a soft metal bar or by pressing them into
the housing.
16. After reinstalling the bull gear and pinion shaft, you must establish
the proper bearing “pre-load” (0.000” to 0.003”) before you operate
the pump.
 Obtain end play readings with a dial indicator and remove the
appropriate thickness of bearing adjustment shims.
 Do not apply silicone liquid gasket material to the bearing retainers

until the bearing pre-load has been properly set.
 Avoid overheating and damaging the pinion oil seal when

reinstalling the pump driveline hub on the input shaft.
7.6.2 Remove the Crankshaft, Connecting Rods, and Crossheads
1. Remove the speed reducer assembly (see7.6.1 Fluid End Repair

Procedures Remove and Disassemble the Speed Reducer).
2. Remove the plunger and seal retainers (see 7.2 Change Plungers
and Packing7.1.)
3. Use a 9/16” wrench to remove the 3/8” cap screws that secure the side
covers and rear cover to the power end housing.
4. Remove the 1/8” cotter pin from each of the twelve (12)
connecting rod bolts.
5. Use a 15/16” wrench to remove the slotted 5/8” hex nuts

from each of the twelve (12) connecting rod bolts.
6. Remove the three (3) connecting rod caps. Avoid damage to the rod
bearing inside each cap.
7. Push each connecting rod/crosshead assembly all the way forward.

Avoid damage to the rod bearing inside each connecting rod.
8. Use a 3/4” wrench to remove the 1/2” cap screws that secure the wrist
pin retainer plate to the crosshead or use a 9/16" wrench to remove
the 3/8” cap screws that secure the wrist pin retainer washers to the
wrist pin.
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Volume 1 of 1
9. Use a slide hammer with 1”-11 1/2 LPT puller thread to pull the wrist
pin from the crosshead. Remove the connecting rod from the
crosshead and take it out of the power end.
10. Rotate the crosshead 90 degrees and remove it through the side of
the power end. Remove the remaining two connecting rods and
crossheads in the same manner.
11. Reattach each match-marked connecting rod cap to its original rod.
If the connecting rod bearing halves will be re-used, tag them for
reinstallation in the same connecting rod or cap.
12. Use a 9/16” wrench to remove the 3/8” cap screws that secure the tach
drive housing to the power end. Remove the tach drive assembly.
13. Use a 9/16” wrench to disconnect the lube oil hose attached to the
main bearing housing inside the power end.
14. Use a 1 1/16” wrench to remove the eight (8) 7/8” nuts that secure the
main bearing housing to the power end. Remove the main bearing
housing and inspect the bearing for wear.
15. Turn the power end housing over on its side so that the crankshaft
extension points straight up. Block up the power end so that it rests
level.
16. Use a 9/16” wrench to remove the 3/8” cap screws that secure the
three bearing retainers against the left hand inner main bearing's
outer face. Lift the crankshaft from the power end.
17. Use a 9/16” wrench to disconnect the six (6) lube oil hoses from the
fittings at the rear of each crosshead guide.
18. Use a 15/16” wrench to remove the two (2) 5/8” cap screws that secure
each crosshead guide to the power end housing.
19. Remove the six (6) crosshead guides and inspect them for wear.
Prior to power end reassembly, thoroughly flush and clean all lubrication
hoses and lube passages.
20. Reassemble the power end in the reverse order of the disassembly
instructions.
Service Manual
Volume 1 of 1
When you reinstall the crosshead slides, avoid torquing the 5/8” cap
screws to more than 35 ft.-lbs. torque. Excessive torque can distort the
surface of the slide and cause crosshead misalignment.
Check the clearance between the top of the crosshead and top
crosshead slide with the feeler gauge from the side opening of the
power frame (not from the rear of the power frame). Clearance between
the top crosshead slide and the crosshead should be between 0.008-
0.012”. If this clearance is not present, remove the bottom slide and
insert appropriate shims between the slide and the power frame at both
the front and rear slide mounts.
When reinstalling the crankshaft, carefully shim the left hand fixed type
inner main bearing so that it has only 0.003" to 0.015” lateral
movement. Carefully shim the main bearing housing and speed reducer
also in order to maintain 0.015” to 0.100” lateral running clearance on
the two outer main bearings.
Torque all cap screws, nuts, etc. properly upon reassembly (see 8.0
Torque Table included in this manual).
Service Manual
Volume 1 of 1
8.0 TORQUE TABLE
Thread
Diameter and Cap Screws, Nuts and Bolts Alloy Steel Studs and Nuts
Thread Pitch SAE Grade 5 SAE Grade 7
Lubricated
Dry Threads Dry Threads Lubricated Threads
Torque Threads Torque Torque
Torque (Ft. Lbs.)
(Ft. Lbs.) (Ft. Lbs.) (Ft. Lbs.)
1
/4” - 20 UNC 6 5 -- --
5
/16”-18 UNC 13 10 -- --
3
/8”-16 UNC 24 16 -- --
7
/16”-14 UNC 39 29 -- --
1
/2”-13 UNC 60 45 -- --
5
/8”-11 UNC 110 80 -- --
3
/4”-10 UNC 212 159 -- --
7
/8”-9 UNC 315 236 425 318
1”-8 UNC 472 354 635 477
1
1 /8”-7 UNC 633 475 900 675
1
1 /4” – 7 UNC 900 675 1270 955
3
1 /8”- 8 NS -- --- 1660 1245
5
1 /8”- 8 NS --- --- --- 2300
3
1 /4”- 8 NS --- --- --- 2400
If you do not have a torque wrench, use a hammer lug wrench to achieve the required
torque on the 1 3/8”, 1 5/8”, and 1 3/4” studs. Tighten each one with a standard wrench
and then turn another 30 degrees (1/12th turn) with the hammer wrench.
Service Manual
Volume 1 of 1
9.0 POWER END ASSEMBLIES AND DETAILED PART LISTS

9.1 Power End Case Assembly
Service Manual
Volume 1 of 1
Table 7 ‐ Power End Case Assembly Parts List
Item Part No. Qty. Description

P64-11-000 POWER END,CASE ASSY
FRAME,MACHINING,POWER END, QPA1000
01 P64-11-001 1
PUMP
02 P60-11-002 1 PLUG,BOTTOM COVER 3" NPT
04 X26-02-028 3 PLUG, 1/2" NPT (4N-08)
05 P64-11-005 1 COVER,TOP
06 P64-11-006 1 COVER,BOTTOM
07 P64-11-010 1 REAR COVER ASSY
08 P64-11-008 1 GASKET,REAR COVER
09 P60-11-009 1 OIL BREATHER
10 X20-08-052 82 HHCS,.375-16 UNC X 1.0",GR 8, PLATED
3
11 X20-27-552 82 WASHER,FLAT, /8" ,ZINC PLATED
14 P64-11-014 2 GASKET,TOP/BOTTOM COVER
15 P60-11-015 2 FOOT PAD COVER
17 X20-07-513 4 FHSCS,.250"– 20 UNC X 0.50" LONG
18 P60-11-018 1 FRONT FOOT-R/H
19 X20-08-789 4 HHCS, .875-9 UNC X 1.5",GR 8,PLATED
7
SET SCREW,SOCKET CAP HEAD, /8"-
20 P60-11-020 4
9 UNC X 0.88"LG
21 P60-11-017 1 FRONT FOOT-L/H
7
24 X20-28-515 4 LOCKWASHER SPLIT, /8”
Service Manual
Volume 1 of 1
9.2 Crankshaft Assembly
Service Manual
Volume 1 of 1
Pedir Table 8 ‐ Crankshaft Assembly Parts List
P64-12-000 CRANKSHAFT ASSY, POWER-END
01 P64-12-001 1 CRANKSHAFT
02 P61-12-002 1 OUTSIDE BEARING HOUSING
03 P60-12-030 12 BEARING RACE RETAINER - OUTER
04 P60-12-028 12 BEARING RACE RETAINER - INNER
05 P60-12-005 2 OUTSIDE BEARING HOUSING GASKET
06 P60-12-006 48 SHIM,BEARING RACE RETAINER - OUTER
1 07 P60-12-024 1 BEARING,MAIN,OUTSIDE,FIXED,HEAVY
1 08 P60-12-025 1 BEARING,MAIN,INSIDE FIXED,HEAVY DUTY
4 09 P60-12-026 4 BEARING,MAIN,OUTSIDEFIXED,HEAVY
10 P60-12-010 8 STUD
7
11 X20-22-909 22 NUT,HEX, /8"- 9 UNC
7
12 X20-28-541 22 WASHER, LOCK, NORD-LOCK, /8” (NL22SP)
13 P60-12-013 66 HHCS,.375 – 16 UNC X 0.88" LG -DRILLED
14 X00-00-150 - WIRE,SAFETY,.051 OD,STAINLESS STEEL
7
16 X20-03-051 14 STUD, /8”-9 UNC X 4” LG, GR B7
17 P60-12-015 84 SHIM,BEARING RACE RETAINER - INNER
SHIM,BEARING RACE RETAINER - INNER,
18 P60-12-016 28
0.04” THICK
SHIM,BEARING RACE RETAINER - INNER,
19 P60-12-017 28
0.02” THICK
5
20 X20-08-576 4 HHCS, /16" – 18 UNC 1"LONG SAE GRADE 5
21 P61-12-004 1 INJECTOR,OIL,CRANKSHAFT
22 P15-08-031 1 RING,RETAINING
GASKET,INJECTOR,CRANKSHAFT,OIL
23 P15-09-031 2
W/#20 ADAPTER
24 P15-04-031 1 RING,SEAL
BUSHING,MAGNETIC,SEAL INSULATOR &
25 P15-03-031 1
COUNTER DRIVE
28 P15-05-031 1 SEAL,MAGNETIC,SHAFT,MSC,65152 REV B
29 000N567120 1 O-RING,NITRILE 70 DURO 120#
30 000N567126 1 O-RING,NITRILE 70 DURO 126#
5
31 X20-28-509 4 WASHER,LOCK, /16”
BEARING RACE RETAINER – INNER (not
32 P60-12-004 9 shown)
Service Manual
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9.3 Crosshead Connecting Rod Assembly
25
16
Service Manual
Volume 1 of 1

Table 9 ‐ Crosshead Connecting Rod Assembly Parts List

P64-13-000 CROSSHEADCONNECTING ROD ASSY,
POWER-END,QPA1000
01 P60-13-100 5 CONNECTING ROD ASSY (INCLUDES ITEM
21, WRIST PIN BEARING)
02 P64-13-004 5 CROSSHEAD
03 P61-13-003 10 CROSSHEAD GUIDE
04 P60-13-004 5 CROSSHEAD WRIST PIN - SHORT
05 X22-01-026 5 RETAINER,RING,GB893.1-86 90ID
06 X04-02-012 20 PIN,COTTER,3.2 x 26 GB91-86
07 P60-13-007 5 CONNECTING ROD BEARING
08 P60-13-008 2 COVER,SIDE
09 P60-13-009 2 GASKET,COVER,SIDE
10 X20-08-044 20 HHCS,.375-16 UNC X 0.750",GR 8, PLATED
11 P60-13-011 20 HHCS,.625-11 UNC x 4.00"LG - DRILLED
15 X00-00-150 - WIRE,SAFETY,.051 OD, STAINLESS STEEL
16 X20-27-552 20 3
WASHER,FLAT, /8", ZINC PLATED
17 P60-13-017 5 PLUG,SOCKET PIPE,1" - 11 - 1/2 TPI
18 P60-13-018 5 THRUST WASHER
19 X20-07-513 5 FHSCS,.250" - 20 UNC x 0.50" LONG
20 P60-34-015 5 PLUNGER STUD ASSY
21 P60-13-006 5 WRIST PIN BEARING
22 P60-13-012 20 HHCS,.625 - 11 UNC x 5.00" LG ,SAE GRADE
8,MODIFIED
23 P60-13-013 20 5
SLOTTED HEX NUT, /8" - 11 NC
24 P60-13-019 10 DOWEL PIN
25 P60-34-016 5 NYLOC
Service Manual
Volume 1 of 1
9.4 Gear Reducer Assembly
(Note: for mounting

hardware, please
refer to Table 8 ‐
Crankshaft Assembly
Parts List, parts 10,
11, and 12)
Service Manual
Volume 1 of 1
Table 10 ‐ Gear Reducer Assembly Parts List

P64-14-000 GEAR REDUCER ASSY,QPA1000
GEAR REDUCER LUBE ASSY (PLEASE SEE
01 P64-14-500 1
SECTION 9.5)
02 P60-14-002 2 COVER GASKET
03 P60-14-003 1 LUBE OIL COVER
05 P64-14-100 2 BEARING, TIMKEN 98316 (INNER)/
98788 (OUTER)
06 P64-14-200 1 GEAR REDUCER FRAME MACHINING
07 P64-14-005 1 BULL GEAR
09 P60-14-007 6 PIPE PLUG,2" NPT,SQ.END
11 X20-08-012 20 HHCS,.5-13 UNC x 1.5",GR 8, PLATED
12 P64-14-010 1 BEARING(BIG) COVER
14 X20-08-092 8 HHCS,.5-13UNC x 1.25",GR 8, PLATED
15 V06-50-322 28 WASHER,SPRING LOCK,STEEL,1/2"ID
16 P64-14-026 1 RETAINER
18 P64-14-017 1 FLANGE TO FIT,GWB 687.55 SERIES
19 P64-14-018 1 RET. WASHER
20 X20-08-142 1 HHCS,1”-14 UNF X 2”LG
21 X20-28-522 1 WASHER,LOCK,1"
22 P64-14-300 1 SEAL ASSEMBLY
23 P64-14-019 1 SPACER
24 P64-14-020 1 PINION
25 P64-14-400 2 BULL GEAR BEARING ASSY
26 X20-08-787 4 HHCS,.375-16 UNC x 0.875",GR 8, PLATED
3
27 X20-28-507 4 WASHER,LOCK, /8"
28 P64-14-012 8 SHIM SET-12",0.2MM THICKNESS
29 P64-14-021 2 SHIM SET (PINION)
30 P64-14-022 2 SHIM SET-12”, 0.1 MM THICKNESS.
31 P64-14-024 1 SHIM,PINION BEARING -0.05 MM
32 P64-14-025 1 SHIM,BULL GEAR BEARING,-0.05 MM
33 P64-14-011 1 SPACER
34 P60-14-550 1 OIL PIPE
35 P64-14-201 4 DOWEL PIN
Service Manual
Volume 1 of 1
9.5 Gear Reducer Lube Assembly
To
Power
End

Service Manual
Volume 1 of 1
Table 11 ‐ Gear Reducer Lube Assembly Parts List

1 7
01 X26-02-721 1 ELBOW, /4"NPTM X /16"-20 JIC37 MALE, STEEL
02 P60-14-513 1 HOSE ASSY MODEL:421 06 06 04 04 04 600
3 1
03 X26-02-296 2 BUSHING, /8" NPTM- /4" NPTF
04 P60-14-512 1 HOSE ASSY MODEL:421 06 06 06 06 06 800
05 P60-14-502 1 ADAPTER
06 P60-14-503 1 TEE
07 P60-14-504 1 TEE,SOFT HOSE
08 P60-14-511 1 HOSE ASSY MODEL:481 06 06 04 04 04 270
09 P60-14-505 2 ELBOW
10 P60-14-506 0 ELBOW,135 DEG
11 P60-14-509 1 HOSE ASSY MODEL:481 06 06 04 04 04 290
12 P60-14-507 0 ADAPTER
3
13 X26-02-287 1 TEE,Z /8" FXFXF
14 P60-14-550 1 OIL PIPE
HOSE ASSY MODEL:421 06 06 06 06 06 1010
15 P60-14-508 0
(USE FOR PUMP)
16 P60-14-514 0 HOSE ASSY MODEL:421 06 06 06 06 06 900
17 P60-14-505 1 ELBOW
Service Manual
Volume 1 of 1
10.0 FLUID END PARTS

10.1 Fluid End Assembly
Service Manual
Volume 1 of 1
Table 12 ‐ 3” Fluid End Assembly Parts List

P64-30-000 FLUID-END,3"
01 P60-30-105 5 DISCHARGE COVER SEAL,2.875 X 3.5 X 0.344
02 P60-30-103 1 DISCHARGE COVER W/2" 1502 FEMALE
03 P60-34-104 1 SEAL RING,2",FIG 1502
04* P64-30-200 2 DISCHARGE FLANGE ASSY
04a* P64-30-201 1 DISCHARGE FLANGE W/2" 1502 FEMALE
04b P60-34-206 1 SEAL,POLYPAK
04c 000P569235 1 O-RING,NITRILE 90 DURO #235
04d P60-34-214 5 HHN,1"-8 NC,L7
04e P60-34-215 5 STUD,1"-8 NC x 3 1/2",L7 FULL STUD
04f P60-34-104 1 SEAL RING,2",FIG 1502
05 P64-34-311 1 MANIFOLD
06 X20-08-010 20 HHCS,.750-10 UNC x 1.5", GR8, PLATED
07 P60-30-401 4 DISCHARGE COVER
08 P60-30-004 5 VALVE SPRING
09 P64-30-005 1 FLUID CYLINDER,3"
10 P60-30-006 5 PLUNGER,3"
11 P8T0005300 5 PACKING,SPS,ASSY,3.0
12 P60-30-007 5 SUCTION VALVE STOP
13 P60-30-600 10 VALVE ASSY
15 P60-30-008 10 SEAT,VALVE
16 000P569244 5 O-RING,NITRILE 90 DURO #244
18 7000010735 5 SUCTION COVER D-RING, 3”

19 P60-30-701 5 SUCTION COVER
20 P60-30-011 9 COVER RETAINER NUT
SCREW,TPFS,1"-12UN x 11.00"LG,HIGH TORQUE
21 P60-34-012 4 FLANGE,GRADE 120M,ROLLED THREADS
3
SCREW,TPFS,1- /8"-12UN x 10.50"LG,HIGH TORQUE
22 P60-34-013 8
FLANGE,GRADE 120M,ROLLED THREADS
23 P60-30-820 5 SEAL,SET,ASSY
25 P06-00-060 5 NUT,PACKING,3"
1
PLUG,PIPE, /4"-18NPT,HEX SOCKET,PLATED (SAME
26 X26-02-009 40
PART WITH V06-37-872)
*When using the longer Discharge Flange (DF):

04 P64-34-200 2 Female DF Assy P64-34-230 2 Male DF Assy
04a P64-34-201 1 Female DF P64-34-203 1 Male DF
Service Manual
Volume 1 of 1
Table 13 ‐ 3 ½” Fluid End Assembly Parts List

P64-34-000 FLUID-END,3 1/2", QPA1000, ASSY
01 P60-34-105 5 DISCHARGE COVER SEAL
03 P60-34-104 1 SEAL RING,2", FIG 1502
04a* P64-34-201 1 DISCHARGE FLANGE, W/2" FIG 1502 FEMALE
04b P60-34-206 1 SEAL,POLYPAK
04c 000P569235 1 O-RING,NITRILE 90 DURO #235
04d P60-34-214 5 HHN,1"-8 NC,L7
04e P60-34-215 5 STUD,1"-8 NC x 3 1/2",L7 FULL STUD
04f P60-34-104 1 SEAL RING,2",FIG 1502
05 P60-34-311 1 MANIFOLD
06 X20-08-010 20 HHCS,.750-10 UNC x 1.5",GR8,PLATED
09 P64-34-005 1 FLUID CYLINDER, 3-1/2" TO 4-1/2"
10 P60-34-006 5 PLUNGER, 3 1/2"
11 P8T0005350 5 PACKING,SPS,ASSY,3.5
13 P60-34-600 10 VALVE ASSY
15 P60-34-008 10 VALVE SEAT,3 1/2",4" & 4-1/2"
18 P60-34-704 5 SUCTION COVER SEAL
SCREW,TPFS,1"-12 UN x 11.00"LG,HIGH TORQUE
3
SCREW,TPFS,1- /8"-12 UN x 10.50"LG,HIGH TORQUE
24 P60-34-017 5 VALVE SPRING SUCTION LIGHT
5 1
25 P06-00-063 NUT,PACKING,3 /2"
1
PLUG,PIPE, /4"-18NPT,HEX SOCKET,PLATED (SAME
26 X26-02-009 40 PART WITH V06-37-872)

Service Manual
Volume 1 of 1
Table 14 ‐ 4” Fluid End Assembly Parts List

P60-40-000 FLUID-END, 4"
03 P60-34-104 1 SEAL RING, 2", FIG 1502
04a* P64-34-201 1 DISCHARGE FLANGE, W/2" FIG 1502 FEMALE
04b P60-34-206 1 SEAL, POLYPAK
04c 000P569235 1 O-RING, NITRILE 90 DURO #235
04d P60-34-214 5 HHN,1"-8 NC, L7
04e P60-34-215 5 STUD,1"-8 NC x 3 1/2", L7 FULL STUD
04f P60-34-104 1 SEAL RING, 2", FIG 1502
05 P60-34-311 1 MANIFOLD
06 X20-08-010 20 HHCS, .750-10 UNC x 1.5", GR8, PLATED
VALVE SPRING, 4" FLUID END, DISCHARGE (SPM
08 P60-40-004 5 TWS600S)
10 P60-40-006 5 PLUNGER, 4"
11 P8T0005400 5 PACKING,SPS,ASSY, 4.0
13 P60-34-600 10 VALVE ASSY
15 P60-34-008 10 VALVE SEAT, 3 1/2", 4" & 4-1/2"
16 000P569244 5 O-RING, NITRILE 90 DURO #244
17 000P569153 10 O-RING, NITRILE 90 DURO #153
SCREW,TPFS,1"-12 UN x 11.00" LG,HIGH TORQUE
21 P60-34-012 4 FLANGE,GRADE 120M, ROLLED THREADS
3
SCREW,TPFS,1- /8"-12 UN x 10.50" LG,HIGH TORQUE
22 P60-34-013 8 FLANGE, GRADE 120M, ROLLED THREADS
25 P06-00-065 5 NUT,PACKING, 4"
1
PLUG,PIPE, /4"-18 NPT,HEX SOCKET, PLATED (SAME
26 X26-02-009 40 PART WITH V06-37-872)


Service Manual
Volume 1 of 1
Table 15 ‐ 4 ½” Fluid End Assembly Parts List

P60-44-000 FLUID-END,4 1/2"
02 P61-34-103 1 DISCHARGE COVER W/2" 1502 F
03 P60-34-104 1 SEAL RING, 2", FIG 1502
04a* P64-34-201 1 DISCHARGE FLANGE, W/2" FIG 1502 F
04b P60-34-206 1 SEAL, POLYPAK
04c 000P569235 1 O-RING, NITRILE 90 DURO #235
04d P60-34-214 5 HHN,1"-8 NC, L7
04e P60-34-215 5 STUD,1"-8 NC x 3 1/2", L7 FULL STUD
04f P60-34-104 1 SEAL RING,2",FIG 1502
05 P60-34-311 1 MANIFOLD
06 X20-08-010 20 HHCS,.750-10 UNC x 1.5",GR8, PLATED
10 P60-44-006 5 PLUNGER, 4 1/2"
11 P8T0005450 5 PACKING, SPS,ASSY, 4.5
13 P60-34-600 10 VALVE ASSY
15 P60-34-008 10 VALVE SEAT, 3 1/2", 4" & 4-1/2"
SCREW,TPFS,1"-12 UN x 11.00" LG,HIGH TORQUE
3
SCREW,TPFS,1- /8"-12 UN x 10.50" LG,HIGH TORQUE
25 P06-00-058 5 NUT,PACKING, 4-1/2"
1
PLUG,PIPE, /4"-18 NPT, HEX SOCKET,PLATED (SAME
26 X26-02-009 40 PART WITH V06-37-872)

Service Manual
Volume 1 of 1
10.2 D-Ring Packing Assembly

Service Manual
Volume 1 of 1
10.3 O-Ring & Backup O-Ring Packing Assembly
Service Manual
Volume 1 of 1
10.4 Packing Assembly 3”
Table 16 ‐ Packing Assembly Parts List (3”)

P8T0005300 PACKING, SPS, ASSY, 3.0
01 P06-00-061 1 RING,SEAL, 3" (O-ring retainer)
D-RING, 3.648" ID X .139" CS X .140" HT
02 7000000456 1
MOLDED
500* 000PBUN239 1 BACKUP,O-RING,90 DURO #239
502* 000P569239 1 O-RING,NITRILE 90 DURO #239
D-RING, 3.272" ID X .139" CS X .140" HT
04 7000000457 1
MACHINED
501* 000PBUN240 1 BACKUP, O-RING, 90 DURO #240
503* 000P569240 1 O-RING, NITRILE 90 DURO #240
06 P902503000 1 PACKING,SPS, HEADER RING, 3.0 X 4.0
PACKING,SPS,VD RING, 3.0 X 4.0
07 P903503000 1
(pressure ring)
1 PACKING,SPS, FEMALE ADAPTER,
08 P904503000
3.0 X 4.0 (spacer ring)
PACKING, SPS, LANTERN RING,
09 P833000790 1 3.0 X 4.0 X 0.730 (Note: 0.790 prior to 12/01/2013)
(oil ring)
PACKING,SPS,OIL SEAL,3.0 X 3.5 X 0.275
11 P906503000 1
(wiper ring)
50 P8A0005300 0 PACKING,SPS,REPAIR KIT A,3.0
*used only before 2011
Service Manual
Volume 1 of 1
10.5 Packing Assembly 3 1/2”

Table 17 ‐ Packing Assembly Parts List (3 1/2”)

P8T0005350 PACKING,SPS,ASSY,3.5
01 P06-00-064 1 RING,SEAL, 3-1/2" (O-ring retainer)
02 7000000459 1 D-RING, 4.772" ID X .139" CS X .140" HT
MACHINED
500* 000PBUN248 0 BACKUP,O-RING,90 DURO,#248
04 7000000458 1 D-RING, 4.272" ID X .139" CS X .140" HT
MACHINED
501* 000PBUN244 0 BACKUP,O-RING, 90 DURO,#244
06 P902503500 1 PACKING,SPS,HEADER RING,3.5 x 4.5
07 P903503500 1 PACKING,SPS,VD RING,3.5 x 4.5
(pressure ring)
08 P904503500 1 PACKING,SPS,FEMALE ADAPTER,3.5 x 4.5
(spacer ring)
09 P833500792 1 PACKING,SPS,LANTERN RING,3.5 x 4.5 x
0.730 (Note: 0.792 prior to 12/01/2013)
(oil ring)
10 P06-00-063 0 NUT,PACKING,3-1/2"
11 P906503500 1 PACKING,SPS,OIL SEAL,3.5 x 4.0 x 0.275
(wiper ring)
12 P06-00-077 1 SPACER,STEEL,4.5" x 5.5" (only on 3 ½”)
50 P8A0005350 0 PACKING,SPS,REPAIR KIT A,3.5
Service Manual
Volume 1 of 1
10.6 Packing Assembly 4”

Table 18 ‐ Packing Assembly Parts List (4”)
Item Part No. Qty Description

P8T0005400 PACKING,SPS,ASSY, 4.0
01 P06-00-066 1 RING,SEAL, 4" (O-ring retainer)
02 7000009312 1 D-RING, FOR 4" TPD600
04 7000000459 1 D-RING, 4.772" ID x .139" CS x .140" HT MACHINED
06 P902504000 1 PACKING,SPS,HEADER RING,4.0 x 5.0
07 P903504000 1 PACKING,SPS,VD RING,4.0 x 5.0 (pressure ring)
08 P904504000 1 PACKING,SPS,FEMALE ADAPTER,4.0 x 5.0
(spacer ring)
09 P834000780 1 PACKING,SPS,LANTERN RING,4.0 x 5.0 x 0.780
(oil ring)
10 P06-00-065 0 NUT,PACKING,4"
11 P906504000 1 PACKING,SPS,OIL SEAL,4.0 x 4.5 x 0.275 (wiper ring)
50 P8A0005400 0 PACKING,SPS, REPAIR KIT A, 4.0
Service Manual
Volume 1 of 1
10.7 Packing Assembly 4 1/2”

Table 19 ‐ Packing Assembly Parts List (4 1/2”)
Item Part No. Qty Description

P8T0005450 PACKING, SPS, ASSY, 4.5
01 P06-00-059 1 RING,SEAL, 4-1/2" (O-ring retainer)
0502* 000PBUN248 0 BACKUP, O-RING, 90 DURO,#248
06 P902504500 1 PACKING, SPS,HEADER RING, 4.5 x 5.5
07 P903504500 1 PACKING, SPS,VD RING, 4.5 x 5.5 (pressure ring)
08 P904504500 1 PACKING, SPS, FEMALE ADAPTER, 4.5 x 5.5
(spacer ring)
09 P834500780 1 PACKING, SPS, LANTERN RING,4.50 x 5.50 x 0.717
(Note: 0.780 prior to 12/01/2013) (oil ring)
10 P06-00-058 0 NUT, PACKING, 4-1/2"
11 P906504500 1 PACKING, SPS, OIL SEAL, 4.5 x 5.0 x 0.275 (wiper ring)
50 P8A0005450 0 PACKING, SPS, REPAIR KIT A, 4.5
Service Manual
Volume 1 of 1
10.8 Seal Assembly

Table 20 ‐ Seal Assembly (used before 2007)
Item Part No. Part No. Part No. Part No. Qty Description
1 1
3" 3 /2" 4" 4 /2" PLUNGER DIA.
Assy P60-30-800 P60-34-800 P60-40-800 P60-44-800 SEAL,SET,ASSY
01 P60-30-803 P60-34-801 P60-40-801 P60-44-801 1 OIL SEAL
02 P60-30-801 P60-34-802 P60-40-802 P60-44-802 1 DEFLECTOR
03 P60-30-802 P60-34-803 P60-40-803 P60-44-803 1 DIAPHRAGM PLATE
GASKET
05 000P569343 000P569346 000P569351 000P569354 1 O-RING
06 P60-30-804 P60-34-809 P60-40-809 P60-44-809 1 WASHER RING
07 X20-28-003 X20-28-003 X20-28-003 X20-28-003 4 LOCKWASHER, SPLIT
1
/ 4"
08 X20-08-007 X20-08-007 X20-08-007 X20-08-007 4 HHCS, .25"-20 UNC x
0.625",GR 8, PLATED
09 X20-08-044 X20-08-044 X20-08-044 X20-08-044 4 HHCS, .375-16 UNC x
0.750",GR 8,PLATED
Service Manual
Volume 1 of 1
Table 21 ‐ Current Set Seal Assembly (used since 2007)
Item Part No. Part No. Part No. Part No. Qty Description
3" (*) 3 1/2" 4" 4 1/2" PLUNGER DIA.
ASSY P60-30-820 P60-34-820 P60-40-820 P60-44-820 SEAL, SET, ASSY
DIAPHRAGM PLATE
02 P60-34-804 P60-34-804 P60-34-804 P60-34-804 1
GASKET
OIL SEAL (METAL
03 P60-30-816 P60-34-816 P60-40-816 P60-44-817 1
BACKED)
OIL SEAL (URETHANE
03* P60-30-818 P60-34-818 NA P60-44-819 1
– NEW)
BOLT HHCS, 0.375-16
04 P60-40-805 P60-40-805 P60-40-805 P60-40-805 4
UNC x 0.750
05 P60-30-807 P60-34-808 P60-40-808 P60-44-805 1 DEFLECTOR HOUSING
BOLT HHCS, 0.375-16
06 X20-08-787 X20-08-052 X20-08-052 X20-08-518 3
UNC x 1.0" GR 8
07 000P569343 000P569346 000P569351 000P569354 1 O-RING
DEFLECTOR SCRAPER
08 P60-30-806 P60-34-810 P60-40-807 P60-44-807 1
-MODIFIED
Service Manual
Volume 1 of 1
11.0 ACCESSORIES
11.1 Useful Pump Data Terms
Acronym Meaning
A Area (square inches)
BHP Brake horsepower
BPM Barrels per Minute (US)
FV Flow Velocity (feet per second)A
GPM Gallons per Minute (US)
GPR Gallons per Revolution (US)
HHP Hydraulic Horsepower 4M
ID Inside Diameter (inches)
ME Mechanical Efficiency
NC Number of Cylinders (per pump)
PD Plunger Diameter (inches)
PSI Pounds per Square Inch
RL Rod Load (pounds)
RPM Crankshaft Revolutions per Minute
SL Stroke Length (inches)
T Torque (feet pounds)
Service Manual
Volume 1 of 1
11.2 Pump Data Formulas
1. Calculate the HHP output when you know the volume and pressure.
GPM x PSI
= HHP
1714
2. Calculate the BHP input required when you know the volume,
pressure and mechanical efficiency.
GPM x PSI
= BHP
(1714 x ME)
3. Calculate the maximum possible pressure when you know the BHP,
flow and ME.
BHP x (1714 x ME)

= PSI
GPM
4. Calculate the maximum possible flow when you know the BHP, PSI
and ME.
BHP x (1714 x ME)

= GPM
PSI
5. Calculate rod load when you know the plunger diameter and
pressure.
PD x PD x .7854 x PSI = RL
6. Calculate the maximum possible pressure at a given rod load when
you know the RL rating and plunger diameter.
RL
= PSI
PD x PD x PD x .7854
Service Manual
Volume 1 of 1
7. Calculate the flow in gal/rev or GPM when you know the plunger
diameter, stroke length and number of cylinders.
PD x PD x .7854 x SL x NC
= GPR
231
GPR x RPM = GPM
8. Calculate the fluid flow velocity through a pipe or hose when you
know the GPM and pipe size.
Pipe ID x Pipe ID x .7854 = internal Area
GPM x .3208
= Flow Velocity
A
9. Calculate the hose size required to maintain a specified flow velocity
when you know the GPM and desired flow velocity.
GPM x .3208
= Internal Area Required
FV
10. Calculate the maximum allowable GPM through a specified hose or

pipe at a specified flow velocity when you know the internal area of
the pipe and the desired flow velocity.
FX x A
= Maximum GPM
.3208
11. Calculate the pinion shaft or driveline torque when you know the
input GHP and pinion shaft RPM.
BHP x 5252
= Torque
Pinion Shaft RPM
Service Manual
Volume 1 of 1
Service Manual
Volume 1 of 1
12.0 TOOLS
Of the tools listed in the following table, tools # 6 & 7 (Seat Puller Assy) are optional. If
needed, please order the Seat Puller Assy separate from the pump. (Drawings of the
tools follow the table on the remaining pages in this document.)
Tool Part No. Qty. Description
- P60-09-001 3” TOOL KIT
- P60-09-002 3 ½” TOOL KIT
- P60-09-003 4” TOOL KIT
- P60-09-004 4 ½” TOOL KIT
1 P60-34-910 1 VALVE COVER REMOVAL TOOL, 2" HEX
2 P60-34-920 1 SLIDE HAMMER
3 P60-34-930 1 PLUNGER WRENCH TOOL, 1 1/2" SQUARE

4 P60-34-940 1 PACKING NUT TOOL, 0.63”
5 P60-34-308 1 VALVE LIFTER TOOL
6 SRV-C0-120 - SEAT PULLER ASSY, LISTING (3")
7 P60-34-926 - SEAT PULLER ASSY, LISTING (31/2", 4" & 41/2")
8 P60-34-936 1 GAUGE COVER REMOVAL TOOL, 0.94”
9 P60-34-951 1 3" NUT, PLUNGER GUIDE TOOL
9 P60-34-952 1 3 1/2" NUT, PLUNGER GUIDE TOOL
9 P60-34-953 1 4" NUT, PLUNGER GUIDE TOOL
9 P60 34-954 1 4 1/2" NUT, PLUNGER GUIDE TOOL
Service Manual
Volume 1 of 1
Tool # 1 ‐ P60‐34‐910 Valve Cover Removal Tool, 2” Hex
Service Manual
Volume 1 of 1
Tool # 2 ‐ P60‐34‐920 Slide Hammer
Service Manual
Volume 1 of 1
Tool # 3‐ P60‐34‐930 Plunger Wrench Tool, 1 1/2” Square
Service Manual
Volume 1 of 1
Tool # 4 ‐ P60‐34‐940 Packing Nut Tool, 0.63
Service Manual
Volume 1 of 1
Tool # 5 ‐ P60‐34‐308 Valve Lifter Tool

Service Manual
Volume 1 of 1
Tool # 6 ‐ Seat Puller Assembly, Listing (3”)

Service Manual
Volume 1 of 1

Tool # 7 ‐ P60‐34‐926 Seat Puller Assembly (3 1/2”, 4” and 4 1/2”)
Service Manual
Volume 1 of 1
Tool # 8 ‐ Gauge Cover Removal Tool, 0.94
Tool # 9 ‐ Nut, Plunger Guide Tool
Service Manual
Volume 1 of 1

Serva - Qpa1000 061814

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QPA1000

1045 Keystone Ave. Phone: 918-266-070

6.0 ROUTINE MAINTENANCE.............................................................................................31

Date Description Author

(this page left intentionally blank)

1.0 GENERAL INFORMATION

WARNING: A WARNING message (in red) indicates a potential personal

CAUTION: A CAUTION message (in orange) indicates a potential hazard

IMPORTANT: An IMPORTANT message (in green) is a reminder about the

RECOMMENDATION: A RECOMMENDATION (in blue) points out facts

1.1 Safety Precautions

1. Wear Personal Protective Equipment (PPE). Review the PPE manual

2. Flush the pump to remove any additives or other harmful chemicals

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

7. Use a remote-operated choke to build pressure in the QPA1000

Never use a fully closed valve to bu8ild pressure in a positive

Do not start the pump if there is a tool attached to the driveshaft.

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

1.2 QPA1000 Pump Description

Optional packing assemblies, valve assemblies, discharge flanges, suction

1.2.1 Performance Data 1

Rated Maximum Brake Horsepower 1000 BHP (746 Kw)

1.2.2 Performance Data 2

Plunger Output Displacement at Pump Strokes per Minute/Pinion RPM

1.2.3 Tachometer Drive/Rate Meter Calibration Specifications

4½ .2355 .00561 .8912 .2479 .00590 .9382

VE - Volumetric Efficiency of pump

GPR - Gallons (US) per Revolution

BPR - Barrels (US) per Revolution

LPR - Liters per Revolution

1.2.4 Identification Plate

1.2.5 Pump Noise

1.3 Replacement Parts

1. The part number and description of each item ordered. (Refer to

2. The quantity of each part, kit or assembly ordered.

4. Your purchase order number.

5. Specify the method of shipment and complete shipping address,

1.4 Shipping and Storage

3. Remove the crankcase breather and plug all openings.

5. Store pump inside in a warm, dry location.

(this page left intentionally blank)

2.0 INSTALLATION DETAILS

2.1.1 Power Source

To avoid overpowering the pump, the prime mover (usually a 2100

The mechanical driveline should have a “Diesel Engine Use” torque

Do not exceed the manufacturer’s recommendations for maximum

 A power shift transmission with integral torque converter and

 If you use a transmission with a high gear or overdrive ratio greater

 If you use a transmission with a torque convertor and/or a low gear

2.1.3 Power End Mounting

2.1.4 Power End Lubrication

2.1.5 Plunger Lubrication

2.1.6 Super-charging System

The QPA1000 requires a centrifugal slurry pump super-charging

2.2 Installation Detail Drawing

2.3 Start-up and Break-in Procedure

2.3.1 Inspection Procedure

6. Piping connections on the super-charge piping system are tight after

8. The suction pulsation dampener is properly pre-charged.

9. There is an adequate supply of cool clean water for testing

2.3.2 Warm-up Procedure (prior to rotating the plunger pump)

 the power end lube pump vacuum reading and

 the power end lube oil pressure and temperature.