Bobma Jedco - Omega F1000 W2250

TABLE OF CONTENTS Section Page No. INSTALLATION PROCEDURE..............................................................................................................1 1.0 Introduction...................................................................................................................................1 2.0 Service .........................................................................................................................................1 3.0 General .........................................................................................................................................1 3.1 Storage .............................................................................................................................1 3.2 Pump Location.................................................................................................................1 3.3 Pump Protection...............................................................................................................1 3.4 Servicing Space................................................................................................................1 3.5 Power End Mounting .......................................................................................................2 3.6 Driveshaft.........................................................................................................................2 3.7 Gears ................................................................................................................................2 3.8 Lubrication.......................................................................................................................2 4.0 Piping .........................................................................................................................................2 4.1 Suction .............................................................................................................................2 5.0 Accessories ...................................................................................................................................2

5.1 Pressure Relief Valve.......................................................................................................2 5.2 Strainer.............................................................................................................................3 5.3 Pulsation Dampener .........................................................................................................3 5.4 Gaskets.............................................................................................................................4

6.0 Pump Installation ..........................................................................................................................4 START-UP PROCEDURE........................................................................................................................5 LUBRICATION SPECIFICATIONS........................................................................................................6 MAINTENANCE INSTRUCTIONS ........................................................................................................7 1.0 Scope .........................................................................................................................................7 2.0 Oil Change ....................................................................................................................................7 3.0 Inspection Intervals.......................................................................................................................7 3.1 Daily ................................................................................................................................7 3.2 Weekly .............................................................................................................................7

3.3 Monthly............................................................................................................................8 3.4 Quarterly ..........................................................................................................................8 3.5 Annual..............................................................................................................................8

4.0 Service Procedures........................................................................................................................8 4.1 Discharge Valves .............................................................................................................8 4.2 Suction Valves .................................................................................................................8

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TABLE OF CONTENTS Section Page No. 4.0 Service Procedures - continued 4.3 Covers and Retainer Nuts ..............................................................................................10 4.4 Plungers .........................................................................................................................10 4.5 Packing ..........................................................................................................................10 4.6 Fluid End........................................................................................................................13

4.7 Wiper Box......................................................................................................................13 4.8 Pony Rods ......................................................................................................................13 4.9 Stay Rods .......................................................................................................................13 4.10 Power End Flange Repair ..............................................................................................15 4.11 Connecting Rod Bearings ..............................................................................................17 4.12 Connecting Rod, Crosshead & Wrist Pin ......................................................................17 4.13 Crankshaft, Bull Gears & Cylindrical Bearings.............................................................19 4.14 Pinion Shaft & Bearings ................................................................................................21 4.15 Power End Lubrication ..................................................................................................22 4.16 Packing Lubrication.......................................................................................................23

5.0 Fastener Torques.........................................................................................................................24 6.0 Critical Dimensions & Clearances..............................................................................................25 LOCATING TROUBLE..........................................................................................................................27 APPENDIX .......................................................................................................................................31 Table 3-1 Lubrication Oils Performance Charts 1300, W1800, W2000 General Dimension Drawing Parts List Drawings Packing Lube System

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INSTALLATION PROCEDURE

1.0 INTRODUCTION

Wheatley/Omega pumps are manufactured in accordance with the highest standards demanded by the industry. Proper maintenance and care will prolong the period of satisfactory service, and reduce costs.

These instructions were written to promote the care, operation and maintenance of your pump. When trouble arises outside the scope of this manual, our Engineering Department and all factory facilities are ready to help you. Please contact us for assistance.

To improve our products we must be informed of the problems and solutions which occur in the field. We request that you send us short reports of your experiences. Include the pump model and serial numbers, operating conditions, problems and the solution. Forward to Omega Pump, ATTENTION: Engineering Department, 1901 West 2nd, Odessa, Texas 79760. Your help will be greatly appreciated.

2.0 PARTS AND SERVICE

Wheatley/Omega maintains a large inventory of replacement parts at all times for prompt service of its product line. To ensure prompt delivery you must include the following information when you place an order. 1. Part number and description (see the Parts List drawings in the Appendix). 2. Quantity of each part required. 3. Fluid end or power end model number and serial number (see the identification tags on

the pump). 4. Your purchase order or requisition number. 5. Designation of the shipping method you prefer. If overseas shipment is involved,

designate the name of the export and crating company you prefer. Parts and Service orders may also be placed through: Omega Pump In Canada: P.O. Box 1151 Wheatley Gaso Inc. 1901 W. 2nd St. 4616 Manhattan Rd. S.E. Odessa, TX 79760 Calgary, Alberta, T2G 4B4 U.S.A. Canada TEL: (915) 337-7402 TEL: (403) 245-4236 FAX: (915) 337-7582 FAX: (403) 243-7909

Wheatley/Omega has qualified service personnel and service facilities for maintenance and repairs on Omega and other well service pumps. The service facility is located in Odessa, Texas.

3.0 GENERAL

Omega pumps, when properly installed, given good care and regular maintenance will operate satisfactorily for a long period of time.

The following paragraphs discuss the general principles that must be considered to insure trouble-free operations.

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3.1 STORAGE All Omega pumps are tested, inspected and protected against corrosion for the period of shipment and installation only. Storage is as detailed in the Appendix under "Short Term Storage and Export Shipping of Pumps".

If the pump is not to be installed at once, refer to the section entitled "Long Term Storage of Pumps" in the Appendix.

3.2 LOCATION OF PUMP

Locate the pump in a clean, accessible place so it can be inspected at regular intervals during operation. Place the pump as close to the liquid supply as possible to make suction piping short and direct. Provide ample head room for crane, hoist or tackle.

3.3 PROTECTION OF PUMP AGAINST SEEPAGE OR FLOOD

If it is necessary to place the pump in a pit, provision should be made to protect the pump from water that may come into the pit from seepage or flood.

3.4 PROVISION FOR MAINTENANCE SPACE

Whether mounted on mobile equipment, a foundation, or in a pit, sufficient room should be allowed for removal of plungers, rods, crankshafts, etc., and/or inspection of wearing parts as recommended in this manual.

3.5 POWER END MOUNTING The following is a general guideline for installing a pump on mobile or skidded units. Bolt each bracket on the power end securely to its platform or skid. Weld alignment bars to the platform or skid to secure by contact the sides of the mounting brackets on the power end. This will limit lateral movement and help in realignment during removal and assembly.

3.6 DRIVE SHAFT

Tube-type Twin Disc or Spicer 1950 drive lines are used to couple the engine clutch or transmission to the pinion shaft. Drive lines are splined on each end for attaching to the transmission or pinion shaft.

As a general rule keep joint angles small for maximum life. Angles should not exceed 5 degrees for normal operations.

Do not neglect drive shaft lubrication. Use a good quality EP grease meeting the NLG1 grade 2 specification.

Grease every one to three months depending on service.

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3.7 GEARS Enclosed helical gears with a 6.35:1.0, 7.00:1.0 or 7.50:1.0 ratios are mounted on both ends.

Recommended lubricant under normal operation is 85W-140 gear oil If equipment is kept in long term storage or is inactive, keep gearbox 90-95% filled.

The lubricant in a new gearbox should be changed after 500 hours of operation. Clean with flushing oil.

Under normal operating conditions, change the lubricant every six months.

3.8 LUBRICATION

Read and follow lubrication instructions as they appear throughout this manual. The power end is pressure lubricated and dependent on a properly operating system with correct lubricants.

4.0 PIPING

4.1 SUCTION PIPING AND CHARGE PUMP The pump suction piping should be direct, free of bends and restrictions and as short as possible. All bends or turns should be either long radius or 45 elbows. The piping should be pressure tested. Adequate provisions should be made for anchoring and supporting the piping spans.

The suction piping diameter should be equal to or larger than the pump's suction diameter. The pipe should not have high spots and should have a continual rise upward toward the pump. The pump must be able to be isolated for servicing; therefore a fully opening block or butterfly valve should be located in the suction piping. All valves in the suction system should have flow areas equal to or greater than that of the inlet line, with minimum pressure drop across them.

The suction piping system should provide a NPSH that exceeds the sum of the NPSH of the pump, all frictional losses, acceleration head, and the negative peak of the complex wave pulsation of the plungers. Cavitation is most often caused by the detrimental effects of pulsation in the suction piping system. Additional suction head may be required if the liquid contains dissolved gases.

A charge pump should be installed as close as possible to the supply source. Improper selection or location of the booster pump can result in increased pulsation and attendant problems. The capacity of the charge pump should be in excess of the capacity of the reciprocating pump. The pressure of the charge pump shall be no less than 30 psi at the reciprocating pump suction at maximum operating capacity.

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5.0 ACCESSORIES

5.1 PRESSURE RELIEF VALVE (PRV) The use of a discharge relief valve of suitable size for the full rated capacity of the pump, set to open at a pressure above the operating discharge pressure required of the pump, is mandatory because of the safety it affords. The relief valve should be placed in the discharge line close to the pump and ahead of any other valves. Full opening, pilot operated, or shear pin relief valves, or burst discs, which require little or no over-pressure to develop fully open flow capacity are often preferable to spring loaded relief valves. Spring types may require considerable over-pressure to compress the spring, before becoming fully open, creating much pump overload. Pressure relief valves have a "set" pressure, which may be described as the pressure at which the relief valve cracks and begins to open, allowing some flow to pass through. As additional pressure is applied, above this "set" or "crack" pressure, the spring loaded relief valve will gradually increase its port area until fully open. When fully open, the relief valve must have sufficient capacity so it will relieve the full capacity of the pump without excessive over-pressure. Available spring loaded relief valves differ among manufacturers in extent of over-pressure needed to fully open the valve. This range is generally 10% to 25% above the set pressure depending on spring design. By choosing a larger valve this increase may be reduced. If an attempt is made to set a relief valve too close to the average discharge pressure, the valve may leak slightly due to pump pulsation. Leakage will quickly ruin the relief valve seat and this condition should be corrected. If plunger size is reduced or increased the relief valve setting must be altered accordingly. Always install a liquid filled pressure gage ahead of the relief valve so it reads the true pump pressure while relieving. The exhaust from the relief valve should always be directed to the supply tank - NOT to pump suction. The line from the relief valve to the tank must be the same size as the discharge line. Calculate all pressure drops in the relief valve line when sizing the PRV. Where possible, pipe the relief valve exhaust so that any leakage can be observed.

5.2 STRAINER

To protect the pump from foreign matter, a suction strainer may be installed with a net area three or more times the area of the suction pipe.

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The strainer must be cleaned frequently to maintain a flow area exceeding the suction pipe area. A clogged strainer will result in pump cavitation and serious damage. Therefore, the strainer must be readily accessible for cleaning and inspection.

A pressure gage should be installed near the pump in the suction line. If the pressure falls below the original start-up pressure, the strainer must be inspected. Where a suction lift is involved, a compound or absolute pressure gage must be used.

5.3 PULSATION DAMPENERS

A good suction and discharge pipe layout for reciprocating pumps of conventional type frequently require no devices to compensate for normal variations in velocity of flow in the piping system. However, in some pump piping systems, especially multiple pump installations, there can be considerable pulsations that are generated due to the system acoustical natural frequencies, and pulsation dampeners are necessary.

The type of pulsation control device (dampener or accumulator) required to control pulsation should be based on the type, size, and speed of the pump, the properties of the liquid, the pressures, operational conditions, and the layout of the piping. The dampener or accumulator best suited to control pulsations in the piping system should be determined from an analysis of the acoustical characteristics of the entire pump piping system, including all of the interconnected pump systems. If pulsation dampeners or accumulators are used, they should be installed as close as possible to the pump flange connection and should be considered as a part of the piping system and not as an accessory of the pump.

If pulsation dampeners or accumulators are a function of the line pressure, provisions should be made to keep the unit(s) charged with nitrogen or similar inert gas in accordance with the equipment manufacturer's recommendation.

In multiple pump systems, the effectiveness of gas charged bladder dampener or accumulator can be compromised unless all accumulators are optimally tuned; therefore, the use of acoustically-tuned, all liquid filter should be considered.

In systems which have a variable discharge static pressure, the gas charged bladders on dampener or accumulator devices can become ineffective and the use of acoustically tuned all-liquid filter devices should be considered.

5.4 GASKETS, PIPE DOPE AND PIPE TAPE

The gaskets, pipe dope and pipe tape used in the piping system are exposed to the same conditions of high or low temperature, pH values, etc., as the pump parts. Careful selection is necessary to avoid joint failure.

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6.0 PUMP INSTALLATION

The following recommendations serve as a guideline for installing an Omega pump on a mobile or skid power unit.

Proper lubrication of the power end and fluid end packing is of major importance for satisfactory performance and satisfactory component life. Read the sections of the manual on lubricant selection and on the lubrications systems.

The Omega pump should be mounted on a flat and level surface with all four corners of the power end fastened to the mobile or skid frame. Mounting brackets can be bolted or welded to the power end frame. Alignment bars welded to the mobile or skid frame and positioned to the pump frame will control lateral movement and provide for alignment when the pump is mounted into place following its removal for service work.

Power can be transferred from an engine or motor to the pinion shaft by either a U-joint driveline or a flexible coupling. A driveline is preferred as alignment is not as critical. Follow driveline or coupling manufacturer's recommendations for concentricity and angular tolerances. Allow 1/8" for pinion shaft end float on couplings.

The pinion shaft will not allow side loads in excess of 300 pounds. Unit designs utilizing chain or belt drive will require a jack shaft drive arrangement.

A charge pump for cavitation prevention is required on the suction side of all Omega triplex pumps. The charge pump should provide a flow rate of 10 to 20% above the flow rate of the triplex pump and a pressure of 30 to 60 PSI at the triplex pump's suction manifold. A suction screen should be provided if trash or rocks are present in the pumped fluid.

A safety shutdown switch is recommended for installation on the power end lubrication system. The switch should be located on the end of the power end lubrication pipe (under the belly of the power frame). Oil pressure should not drop below 30 PSI. Oil pressure and oil temperature gauges should also be installed.

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START-UP PROCEDURE 1.0 Verify pump has been properly installed and that related equipment is operational. 2.0 Open the suction line block or butterfly valve. Verify discharge valves are open and relief valves

are operational. 3.0 Pumps must undergo a break-in run before being put into service at rated load. The first few

hours of testing are usually performed at the factory. However additional break-in occurs up to approximately 100 hours of service. For example, particles off various internal parts are emitted into the oil. Eventually this will cause contamination of the lubrication system and potential pump failure if not frequently checked during the break-in run. The following steps should be followed: 1. Fill the pump oil reservoir and stuffing box lubricator reservoir with the lubricants as

indicated in Table 1 on the following page. Prime the power end lubrication pump. Check all drain plugs for any leakage and tighten as necessary.

2. Be sure that all guards, covers, and shields are in place. Remove only the inspection

covers on the power end to observe oil flow. 3. Clean plungers at back of stuffing box. Squirt oil on plungers. 4. Lock the pump drive (transmission or clutch should be in neutral). Start engine and run

at idle. Check all crossheads, wrist pin bushings, main bearings, rod bearings, pinion bearings and gears for proper lubrication.

5. Increase engine RPM to full RPM. Check the vacuum gage reading at the power end

lubrication pump suction. Reading should be less than 10 inches Hg. Check lubrication pump discharge gage reading. Pressure should be 60-80 PSI. Check the entire lubrication system for leaks. Relief valve on discharge side of lubrication pump should be set at 100-125 PSI.

6. Check oil reservoir level. The filling of hydraulic hoses reduce oil level in sump. Add

oil if necessary. 7. Operate charge pump. Bleed any trapped air from the fluid end. 8. Reduce engine speed. Operate triplex pump at 70 to 80 RPM and no pressure for 1/2

hour. Oil temperature should not climb above 140o F. Observe power end for leakage or unusual noise. Lubrication pump vacuum gage reading should not fall below 10 inches Hg. If it does, filters may be clogged; change as necessary. Discharge pressure of lubrication pump should exceed 50 PSI.

9. Run pump at 70-80 RPM and 25%, 50%, 75%, 100% of operating pressure for 1/2 hour

each. Observe oil pressures and temperatures. Oil temperature should not exceed 180o F.

10. On pumps equipped with a transmission, run pump for 1/2 hour in each gear range at

100% operating pressure. Again observe oil pressures and temperatures.

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START-UP PROCEDURE

11. Shut pump down and let cool before beginning normal operations. Change oil and filter elements within the first 50 hours of operation. Clean strainers when changing oil.

12. If power end is too hot to touch, check temperature. If oil temperature is above 180o F,

stop pump and allow cooling to ambient temperature. Repeat break-in run. If oil temperature continues to exceed 180o F, stop the pump and refer to "Locating Trouble" in Maintenance Instructions.

4.0 See "Inspection Intervals and Descriptions" in Maintenance Instructions.

TABLE 1: LUBRICATION SPECIFICATIONS

POWER END LUBRICATION

Type of

Service

Ambient Temperature

Safe

Operating Temperature

Viscosity SUS @ 100 O F

Pour Point

Timken Rating 1 bl.

ISO Grade

AGMA Grade

General 0-95 O F

Up to 180O F

1165 10O F 65 220 5 EP

Hot Above 95 O F

Up to

200O F 1710 10O F 65 320 6 EP

Cold Below 0 O F

Up to

130O F 350 5O F 60 68 2 EP

Refer to Appendix for equivalent lubrication manufacturer specifications.

PACKING LUBRICATION

Liquid Pumped

Ambient Temperature

Lubricant

Water, Saltwater Above 0 O F

Rock Drill Oil 100 General Service Below 0 O F

Rock Drill Oil 46

Petroleum Products Above 10 O F Straight Mineral Oil Any Below -20 O F

Brake Fluid

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MAINTENANCE INSTRUCTIONS ROUTINE INSPECTION AND SERVICE INTERVAL 1.0 SCOPE

The following maintenance checklist is intended to serve as an INITIAL GUIDELINE ONLY under normal usage and operating conditions. Additional items or inspection interval changes should be recorded in the pump service logs. In addition, some items may be replaced at regularly scheduled intervals to prevent their costly emergency replacement. Consult factory for specific recommendations.

2.0 OIL CHANGE

Numerous factors determine oil change intervals. Should the oil become contaminated by any of the following operating and/or environmental conditions, immediate oil draining and replacement (after thorough flushing and cleaning of the power end with kerosene) is recommended. Daily oil inspection is recommended below, and oil change intervals are stated in paragraph 3.4.

2.1 WATER - from oil seal, wiper seal, breather cap or gasket leakage. 2.2 SOLIDS - from initial break-in as a result of first use as a new or rebuilt power end. 2.3 DUST, SAND OR DIRT - from air-borne sources through the shaft and wiper seals or

breather cap. 2.4 CORROSIVES - from pumpage vapors or gases through the crankshaft seals or breather

cap. 3.0 INSPECTION INTERVALS AND DESCRIPTIONS

3.1 DAILY OR EVERY 24 HOURS OF PUMP OPERATION Normal power end and fluid end operating conditions (temperatures, quiet and smooth operation). Check Oil Levels. Crankcase and, if applicable, packing lubricator and gear reducer (Oil Levels). Power end and fluid end gaskets (leakage). Packing and gland nuts snug (excessive leakage, unsuitable materials). Always check with pump driver off. Gauges in good operating condition. Cradle area (clean and properly draining). Drive couplings (for oil or grease leakage). Fluid end operating pressures (not above specified nameplate values).

All fasteners secure, especially stay rods and nuts on power end to fluid end and bearing housings (leakage & movement). Always check with pump driver off.

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MAINTENANCE INSTRUCTIONS

Pump power end pressure lubrication to be 40 PSI minimum at normal operating temperature. Normal oil pressure is 60 to 100 PSI at an operating temperature of 130 to 160 degrees F. Vacuum on power end lubrication pump should not exceed 10 inches Hg (mercury). Power end oil temperature should not exceed safe operating temperatures as shown in Table 1. Packing lubricator pumps (all functioning, proper drip rate).

3.2 WEEKLY OR EVERY 170 HOURS OF PUMP OPERATION

Crankcase and gear reducer (solids and/or liquids contamination, sample oil from drain connection, preferably while pump is running). NOTE: If the pump is new or has received a recent major over-haul

(connecting rod bearings, wrist pins, bushings, end bearings, etc.,) the oil should be changed at this interval. prior to adding new oil, crankcase cover should be removed and all exposed interior surfaces wiped clean. Also, check torque of all connecting rod bolts prior to crankcase cover replacement. Clean or replace oil filter element.

All strainers, foot valves and any other suction line piping components (free of restrictions and in proper working order). Drive coupling (joint secure).

Plungers and pony rod connections (tight).

3.3 MONTHLY

Crankcase breather (clear and free of debris).

Wiper box oil seals (leakage).

Lubricator lines and connections (for leaks and crimps).

Oil filter element (clean in kerosene or replace).

Proper torque on stay rods.

Valve disc/body and seat sealing surfaces (excessive wear, pitting, wire drawing and solids imbedding).

Valve o-rings and inserts (not torn or worn).

Wiper box seals/packing and o-rings to include wiper box o-rings (leakage from and/or into power end)

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3.4 QUARTERLY Change power end oil and clean sump.

Crankshaft oil seals (leakage, free of paint, cracked or weather checked, excessive heat).

Drivelines (lubricate, check U-joint seals and check bolt torques).

Valve springs (broken or compressed). Plungers and pony rods (scored, worn or damaged).

Pump mounting bolts (tightness).

3.5 ANNUAL Schedule disassembly and inspection of complete pump, concentrating on:

Crankshaft throw/pin surfaces Crankshaft bearings & oil seals Wrist pins and wrist pin bushings Power end pressure lube pump Plungers and pony rods Connecting rod bearings Wiper box seals and o-rings Stuffing box packing , bushings and gland nuts Valve assemblies Fluid end gaskets and seals Helical gears, bearings and shaft seals Suction manifold o-rings

4.0 SERVICE PROCEDURES

WARNING

Before doing any maintenance work on the pump or accessory equipment, disable engine or disconnect the coupling between engine and triplex pump. Be positive that accidental starting of equipment CANNOT happen! Your life depends on it.

4.1 DISCHARGE VALVES The discharge valves are located beneath the valve covers in the upper part of the fluid cylinder body (see Fig. 1). To inspect and possibly replace valves, it will be necessary to remove the retainer nuts and discharge covers. The retainer nuts are removed using a hex wrench for hex retainer nuts and a steel hammer for knock-off retainer nuts. The discharge cover is removed using a cover puller. Refer to parts list for tool part numbers.

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The valve spring can be lifted off the valve body. The valve body can be turned off the valve seat. Remove the valve seat using a seat puller and jack as shown in Fig. 2. Be careful not to scratch the tapered seating surface of the fluid end.

4.2 SUCTION VALVES

The suction valves are located beneath the plunger and cage in the lower part of the fluid cylinder body (see Fig. 1). To inspect and possibly replace the valves, first remove the retainer nuts and cylinder heads. If the plunger is forward, rotate the pump until the plunger reaches its back position. Remove the cage and spring retainer. Turn the valve body off the valve seat.

If the suction valve seat needs removed, it will be necessary to remove the discharge valve body as instructed above. The discharge valve seat does not need to be removed as the puller rod passes through it. Refer to Fig. 2 for suction valve seat removal.

4.3 INSTALLING VALVES, COVERS AND RETAINER NUTS

Before replacing the valve seats, clean the fluid end seat bores thoroughly with a clean solvent. Smooth any scratches or nicks with emery cloth. Taper surfaces must be Clean and Dry before installing seats. Inspect valve seat o-rings and replace if damaged.

Valve seats should be Driven into the seat tapers until firmly seated. This is done by using a flat steel disc or old valve body over the seat and striking a piece of pipe or tubing with a hammer as shown in Fig. 3. Two hammer blows should be enough for adequate seating.

Inspect the inserts on the valve body and replace if damaged. Apply thread compound to the threads on the valve body and thread onto the valve seat.

Clean the cover bores with a solvent. Smooth any scratches or nicks with emery cloth.

Reassemble springs, cages, covers and retainer nuts. Inspect o-rings and backups on covers and replace if damaged. Apply a film of oil to o-rings before dropping or bumping covers into place. Use of the cover puller will assist in centering the cover into the bore.

Light bumping of the covers with a hammer or hammer handle may be necessary to start the o-ring in the bore. Excessive hammering should not be required and is a sign of a bore or cover tolerance problem or damage.

CAUTION

When installing the retainer nuts, do not "force" the thread when tightening. If the retainer nuts are machined correctly and the threads on the nuts and fluid end are not nicked or otherwise damaged, they should thread with relative ease (50 ft.-lbs. or less with a hex wrench). Light hammering of the nuts after they are flush will insure no leakage. However excessive hammering of the nuts before they are flush will only damage threads.

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Valves will "seat" further upon adding pressure to the fluid end. It is preferred that clean water be used to "seat" the valves at rated pressure before pumping fluids with particles.

4.4 PLUNGERS

Plungers are removed through the fluid cylinder bore (Fig. 1) with the following steps:

1. Remove the cylinder head retaining nuts and covers using the hex head wrench for hex retainer nuts, hammer for knock-off retainer nuts and cover puller for the cylinder heads.

2. Disconnect rod clamp from the plunger and pony rod by using a socket wrench. 3. Loosen the gland nut on the fluid cylinder using a spanner rod. 4. Slide the plunger through the cylinder opening. Threaded holes on the cylinder head

and plunger are for attaching a cover puller to assist in removal.

CAUTION

Handle the plunger with care. Any nicks on the coated surface of the plunger may cause frequent packing failure. The clamp end of the plunger is a close tolerance fit and must not be damaged.

4.5 PACKING

Packing is available in V-ring style as shown in Fig. 4. The V-ring set consists of a lantern ring with a poly-pak seal, a throat bushing, a header ring, and two V-rings.

REMOVAL AND INSTALLATION PROCEDURES

The plunger and gland nut must be removed before removing packing. See above section for plunger removal. Use a brass or wooden bar with a hammer and tap the packing set back through the packing bore. It will be necessary to work through the cylinder head bore and place the bar against the throat bushing. The following steps should be followed for packing installation:

1. Check throat bushings, lantern rings and gland nuts for scratches and nicks.

Rework if possible or replace worn parts. 2. Clean the stuffing box bores and check for excessive wear. It may be necessary

to use an inside micrometer and compare bore dimensions to the pump's allowable tolerance. Packing will not seal correctly or have a satisfactory performance life if the bores are not in good condition.

3. Lubricate the packing rings, o-rings, poly-pak seal and stuffing box bores with a

clean motor oil.

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4. Push the throat bushing, header ring, packing rings and lantern ring into the stuffing box bore. Note from Fig. 4 the direction of the "V" on the packing. Care must be taken not to damage the packing lips on installation. Each ring of packing must be installed separately due to the close fit of the ring to the bore and the dexterity required to push the ring in.

5. Thread the gland nut into the fluid end. Use a spanner wrench to tighten the gland

nut until it is snug. Back the gland nut off a turn for assisting in plunger installation. 6. Lubricate the plunger surface with a light film of oil. Push the plunger through the

cylinder head bore and center the plunger on the header ring and packing. Use the puller bar (on larger plungers a chain and hoist) to assist in handling the plunger. It may be necessary to use a brass bar and hammer to push the plunger past the header ring and packing.

7. Install the rod clamp. The mating surfaces of the plunger and the rod clamp must

be clean for a good interference fit. 8. Tighten gland nut until it is snug (approximately 100 ft.lbs.) 9. Be positive plunger oiling line is installed and the lubricator operating correctly

before starting pump.

WARNING When restarting equipment keep away from high pressure areas of the pump. Be sure that any fellow workers or spectators are back behind the engine or even away from the unit. High pressure components can fail upon start-up and may cause serious injury or death.

4.6 FLUID END WARNING

Disable the power unit (engine, motor, etc.) before doing any maintenance or service work. To remove the fluid end the following steps should be taken:

1. Disconnect suction and discharge lines and any accessories such as a stroke

counter, pressure gauge or relief valve. 2. Remove rod clamp between plunger and pony rod. Shove the plunger a short

distance into the fluid end to protect the plunger during the fluid end removal. 3. Connect a chain or line between a power hoist and the fluid end. Tighten until

snug only.

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4. Remove all twelve stay rod nuts from the fluid end with a 2-3/4" hammer wrench.

5. Pull the fluid end horizontally away from the power end until the fluid end

clears the stay rods. Use caution and stand clear as the fluid end may rapidly swing if the load is not centered on the lift. Once clear of the stay rods, the fluid end can be lifted or carried to a work area.

Once the fluid end is replaced, refer to the section on stay rods for torque procedure.

4.7 WIPER BOX

Each wiper box assembly, as shown in Fig. 5, is attached to the power end by four, 5/8" cap screws. After removing the plunger, clamp, and wiper box cap screws, the wiper box will slide out. It is necessary to disconnect the plunger when installing oil seals. The seals are press-fit into the wiper box; use a seating disc to avoid damage or distortion to seal case.

Oil the pony rod before installation of wiper seals and to avoid damage of seal lips. Worn, pitted, or scored pony rods must be replaced to avoid damaging seals and to retain and protect the crankcase oil.

Upon reassembly torque the cap screws on the wiper box

4.8 PONY RODS

The pony rod as shown in Fig. 6 is fastened to the crosshead with six, 3/4" cap screws and is joined by a clamp to the plunger. To remove a pony rod, first remove the plunger clamp. Push the plunger into the fluid end. Remove the wiper box and seal as instructed in Sec. 4.7.

Unbolt the pony rod from the crosshead. Remove the pony rod through the space between the stay rods. Inspect the face of the pony rod for nicks and burrs; repair if present. A damaged face can cause misalignment and premature component wear.

Upon reassembly, torque cap screws on the plunger clamp before operating pump.

4.9 STAY RODS The following steps should be followed to remove, inspect and install stay rods.

1. Twelve, 1-3/4" - 8 thread nuts were originally torqued to the stay rods at 2600 ft.-

lbs. A special torque wrench is required to remove the nuts from the stay rods and the stay rods from the power end. We recommend a Hytorc model HY-4ULC continuous ratcheting torque wrench with 3050 ft.-lbs. capacity. Other hydraulic-powered torque wrenches may be suitable.

15


2. Remove the nuts and fluid end to change a stay rod. If the stay rod is to be reused, do not flame cut and weld a stay rod to assist in procedure.

3. Remove the stay rods. Stay rods were originally torqued at 1000 ft.-lbs. Inspect

all stay rods for cracks by dry magnetic particle or wet dye penetrant tests. Focus on the thread and thread relief areas.

4. Clean and oil both the power end threads and the stay rod threads. Remove any

nicks or burrs at the power end and fluid end that are in contact with the stay rod ends to assure proper alignment of power end to fluid end. Stay rods are precision machined with shoulder-to-shoulder dimensions of +.001. Surface of fluid end flange (nut side) should be smooth and flat within +.001.

5. Attach all stay rods to power end and evenly torque to 1000 ft.-lbs of torque.

6. Slide fluid end onto stay rods, attach nuts, and evenly torque to 2600 ft.-lbs.

Tighten in the sequence shown in Fig. 7.

4.10 REPAIR OF THREADED STAY ROD BOLT HOLES ON POWER FRAME FLANGE The 1-3/4"-8UN threads on the Omega power frame may be damaged beyond use. This damage is generally caused by excessive loading on the stay rods which causes thread "pulling" and failure.

It is common practice to bore the threaded holes to a diameter beyond the major thread diameter, add filler metal by welding and then re-machine to the original thread specifications. Omega Pump does not recommend this method of repair due to possible strength reduction of the steel in the heat affected zone of the weld and general uncertainty in guaranteeing the welding is of acceptable quality. Omega does recommend the installation of threaded plugs in the power frame. Machine the threaded plugs to dimensions and tolerances as shown in Figure 8. The damaged holes will be bored to an internal 2-1/2" 8UN-3B thread with dimensions, tolerances and counterbore as shown in Fig. 9.

Before installing the plugs, coat the threads with Loctite 277 thread compound. Install the threads and tighten with a pipe wrench or other locking wrench to a minimum of 200 ft.-lbs of torque.

Refer to Fig. 9 and the following steps to complete the repair procedure.

1. Cut the excess material from the plugs and machine the face plate to within 0.002

perpendicular with the crosshead bores. Take as light a cut on the flange face as possible to maintain its thickness.

2. Drill, counterbore and tap 1-3/4-8UN-3B threads.

16


3. Drill edge of flange for a 0.375 dowel pin. Note the depth of the dowel pin hole should prevent breakthrough into the internal thread of the plug.

4. Drive the dowel pin into the hole.

4.11 CONNECTING ROD BEARINGS

WARNING

Disable the power unit before doing any maintenance work.

The connecting rod and rod bearings are shown in Fig. 10.

To view the connecting rods, bearings and crankshaft, remove the rear cover from the power frame.

To remove the bearings, first remove the two, 1" cap screws joining the connecting rod cap to the connecting rod base. Remove the rod cap and bottom connecting rod bearing.

NOTE: The rod cap and rod base are matched marked for correct reassembly.

Be careful not to lose dowel pins and shims during disassembly. Use a rubber or wooden hammer to tap a bearing away from cap or base (bearing housing). Clean the new bearings and housings before replacing.

When installing new bearings and shims, match the contour of the shim with the contour of the bearing. If the shim protrudes past the bearing, grind it back to fit. When replacing rod cap keep both dowel pins in place. Match the marks on the rod cap and base. Use 450 ft.-lbs. of torque on the rod cap screws. Move the bearing housing from side to side to check that the bearings turn freely on the crankshaft. If new bearings have been installed, refer to the start-up procedure before operating pump.

4.12 CONNECTING ROD, CROSSHEAD AND WRIST PIN

WARNING Disable the pump power supply before doing maintenance work.

Figures 6, 10, and 11 show the parts assembly of the connecting rod, crosshead, crosshead slide and wrist pin. The W1300 and W1800 use a one-piece connecting rod as shown in Fig.10, while the W2000 is a bolted connecting rod as shown in Fig.11. To view these components in the power frame, remove the top and rear covers.

The connecting rod and crosshead are removed as an assembly through the front (fluid end side) of the power frame. Refer to previous sections and remove the fluid end, stay rods, pony rods and wiper boxes.

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Rotate the crankshaft until the connecting rod bearing housing to be removed is in the upper middle position. Use an air impact wrench with a 1-1/8" socket to remove the six 3/4" nuts from the studs. Use the jacking screw holes to separate the connecting rod from the bearing housing. Remove the connecting rod and crosshead through the front of the power end.

The wrist pin must be removed in order to separate the connecting rod from the crosshead. The following instructions are for the two types of connecting rods.

W1300 AND W1800: Remove the wrist pin lock screw and set screw from the front of the crosshead. Remove the wrist pin from the crosshead. Remove the connecting rod from the crosshead which exposes the bronze thrust seat inside the crosshead. Remove the four Allen head cap screws from the thrust seat keepers.

W2000: Remove the 1-1/4" cap screw and pull the connecting rod off the two dowel pins and away from the crosshead. The wrist pin will now slide out of the wrist pin bushing. Remove the set screws and press the wrist pin bushing from the crosshead.

Check all components for wear and replace if necessary. Check wear on the crosshead guide sleeves. To replace guide sleeves, press from the power frame. Clean components and power end crosshead guide sleeve bores.

Upon reassembly of the wrist pin on the W1300 and W1800 models, the wrist pin set screw hole must align with the crosshead set screw. Press wrist pin bushings into crossheads. Push wrist pins into bushings and measure clearances with feeler gauges.

Upon reassembly the oil groove holes of the crosshead guide sleeves and crossheads must be on top and in alignment.

Bolt connecting rods to rod bearing housings and torque to specification.

Before reassembly of covers, pony rods, stay rods and fluid end, operate the power end. Rotate at 20-30 RPM to confirm parts are in good working order and oiling correctly.

Assemble covers, pony rods, wiper boxes, stay rods and fluid end. Operate pump per start-up procedure outlined in a previous section to break in new components. Observe power end oil temperature when applying full load. Temperature should stabilize below 180 degrees F within four hours

4.13 CRANKSHAFT, BULL GEARS AND CRANKSHAFT CYLINDRICAL

BEARINGS

The crankshaft and bearing assembly are shown in Fig. 12. Remove the rear cover to inspect the crankshaft. Follow the previous sections for connecting rod (shell bearing) removal and inspection. Remove the gear inspection covers to view the gears.

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A clean area and heavy lifting equipment are necessary should removal of either the crankshaft or one of the crankshaft bearings be required. Drain oil from the power frame. Remove the fluid end, plungers, wiper boxes, and stay rods as instructed in the previous sections.

Disconnect the connecting rods from the connecting rod housings. Slide the connecting rods, crossheads, and pony rods forward as an assembly until the connecting rod bumps the guide sleeves. Leave the assemblies in the power frame for convenience.

Remove the rotary unions, crankshaft and pinion seal retainers and drive coupling from the pinion shaft. Remove both gear covers.

Remove both bull gears. Remove the four 1-1/4" cap screws and the 1/2" set screw that fasten the bull gear to the crankshaft. Install two of the 1-1/4" cap screws in the threaded holes on the gear to push the gear away from the crankshaft. The gear will have to spiral as it comes off, due to the helical form of the teeth. Use care when removing to prevent gear tooth damage. Turn the connecting rod bearing housings so the rod faces are to the outside of the crankshaft. This will prevent the crankshaft from falling through the power frame when the frame is turned over. Turn the power frame on its side and block it to a level position. Also place a block under the end of the crankshaft.

Turn all connecting rod bearing housings so the rod faces are towards the center of the crankshaft for clearance through the cylindrical bearings. Attach two 1-1/4" UNC eyebolts to the crankshaft end and pull the crankshaft from the power frame.

Note: If is not advisable to install new bull gears, pinion or crankshafts in the field.

Gear timing (correct backlash) is important and should be done at a service center. The keyway on the second bull gear installed has to be marked upon installation to the pinion gear. The bull gear then has to be removed and the keyway cut.

To remove the cylindrical bearings (main bearings) from the crankshaft, first remove the snap rings from the crankshaft, first remove the snap rings from the crankshaft. Apply a now amount of heat to the bearings and tap them from the crankshaft. Do not apply heat from a torch to bearings being installed on the crankshaft. Instead, expand bearings by immersion in a heat oil bath before installation. Install snap rings on the crankshaft and braze each in two different locations to keep them in place. Do not braze the snap rings to the crankshaft.

To remove the outer bearing race, first remove the snap rings from the power frame. Use a bronze bar and hammer the race from the power frame bore. Shrink the outer bearing race with either dry ice or by placement into a freezer for an hour before installation. Install the snap rings in the power frame and braze each in two different locations to keep them in place. Do not braze the snap rings to the power frame.

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Before installing the crankshaft, flush its oil-ways to remove any foreign particles. Install the connecting rod bearings and housings on the crankshaft. Inspect the power frame mating surface for the gear thrust ring and polish if necessary.

Install the crankshaft in the power end. Place a block underneath the bottom to keep the crankshaft from going in too far. Install the thrust rings on the gears.

Install the second bull gear. If new bull gears are being installed, it will be necessary to install, mark, remove and key this gear to properly time (limit backlash) between both gears. The backlash should be 0.016" to 0.022".

With both bull gears on the crankshaft and cap screws properly torqued, the crankshaft should have 0.040" to 0.060" end play.

Assemble connecting rods, gear covers, seal retainers and rotary unions. Operate at 20 to 30 RPM to check operation and oiling.

Assemble wiper boxes, stay rods and fluid end. Follow start-up procedure for break-in of components.

Install one bull gear on the crankshaft with four 1-1/4" cap screws, key and set screw. Turn the power end upright taking care not to let the crankshaft slip from the bearing races.

4.14 PINION SHAFT AND PINION BEARINGS

The pinion shaft, bearings and gears are shown in Fig. 13. It will be necessary to drain the oil from the power end and to remove the top and back access covers to inspect the pinion.

To remove the pinion shaft or bearings, it will be necessary to remove the gear covers and bull gears. follow the previous section for bull gear removal.

Remove both the pinion bearing housings from around the bearings. Before removing the bearing housings, match mark the housing and power frame. Some of the bearing housing cap screws are countersunk to avoid contact with the bull gear.

The pinion shaft can be pulled from either end of the power frame. Remove the roller on the pinion bearing opposite the side that the pinion shaft will be pulled. To remove the rollers, tilt the outer race and pick the rollers off. Keep a bucket below the bearing as some rollers will probably fall while being removed.

Pull the pinion shaft with care not to damage the exposed bearing races. Tap or use a bearing puller to remove the pinion bearings from the shaft side.

When assembling the pinion, install the pinion bearing and housing on the side that will go into the power frame last. Place the bearing into a warm oil bath to expand the bearing for easier installation. Push the pinion shaft through the power frame until the bearing housing is in the frame bore. Match the housing mark to the power frame mark

20

(the countersink screws need to be where the bull gear travels). Bolt the housing into place.

Install the second pinion bearing on the pinion shaft. Start the pinion housing over the bearing. Use two lengths of 3/4" all thread or two long cap screws for loose attachment of the housing to the frame. This will assist in aligning the housing over the bearing. Tap the housing into place around the bearing. Install the cap screws through the housing into the frame and torque to specification.

Note: The pinion shaft should rotate freely by hand.

Install bull gears, gear covers, rotary union and pinion seal retainer. Install coupling or PTO flange to the pinion shaft. There should be at least 1/8" clearance between the flange face and pinion seal carrier to allow for pinion end float.

Note: It is not practical to install a pinion shaft in the field. One bull gear

will need to be retimed and re-keyed for proper installation.

4.15 POWER END LUBRICATION SYSTEM The lubrication system to the triplex power end includes an externally mounted hydraulic oil system which provides oil under pressure to a distribution pipe located under the power frame. Oil flows from the distribution pie through hose to a rotary union threaded into both ends of the crankshaft and through separate hoses to the gears, crosshead slides and main bearings. The lubrication of the power frame is shown in the power end parts list drawing in the Appendix.

The power end requires an oil lubrication system with a flow rate of 30 to 35 USGPM and a pressure of 60 to 80 PSI. Specifications for the oil are shown in Table 1 and an oil manufacturers' list is shown in the Appendix.

Omega will provide the pressure lubrication system components and necessary sump as an option. Engineering design assistance is also available upon request. A typical lubrication system flow diagram is shown in Fig. 14.

The major components of the lubrication system are the gear pump, suction and pressure hoses, oil sump/reservoir, filter, relief valve, oil cooler, vacuum gauge, pressure gauge, oil pressure shutdown switch, and oil temperature shutdown switch-gauge.

A suction strainer is not recommended for this lubrication system. The heavy oil used will cause a high pressure loss across the strainer and cavitation of the gear pump will result.

The suction hose should be 2" inside diameter and wire reinforced to prevent collapse. The pressure hoses, including the return hose from the cooler, should be 1-1/4" inside diameter. The hose form the relief valve to the tank can be from 1" to 1-1/4" inside diameter. It is recommended that all hoses be one-wire braid hydraulic type for resistance to kinking and damage.

The oil sump should have a capacity of 30 U.S. gallons and a minimum depth of 8 inches. It should also include a breather/filler cap and easily assessable dipstick. A bottom mounted drain plug, and 2" fitting in the side for an optional sump heater are suggested

21

additions. A 1/4" pipe fitting for installation of a temperature gauge is also recommended.

An oil filter is to be installed in the discharge line of the system. Recommended requirements include: a double length elements with 20 to 25 micron filtration, a visual indicator for filter change-out, and a 25 PSI pressure drop by-pass. The filter should be rated for a maximum working pressure of 300 PSI. Selection of the filter must be based on the use of 90 weight gear oil at a flow of 35 USGPM.

A relief valve is required in the discharge line for safety of personnel and equipment. The relief valve should be factory set at 125 PSI. Do not readjust the set pressure, for troubleshooting purposes, unless you are qualified to do so. The relief valve should be sized for bypassing 35 USGPM of cold 90 weight gear oil with at a maximum pressure drop of 25 PSI.

WARNING

Do not operate the lubrication system without a properly sized and operating relief valve.

An oil cooler will be required unless the pump is operated for less than two hours at a time in cool climates with an ambient temperature of less than 60o F. The cooler should be sized for 35 USGPM flow of 90 weight gear oil and have at least 1-1/4" inlet and outlet connections. A 65 PSI bypass check valve should also be provided to bypass, and not to cool, cold 90 weight gear oil. The cooler should be mounted in front of a radiator fan (diesel/gasoline engines) with prior approval from the engine manufacturer or distributor. If a radiator fan is not available, a separate engine or electric motor driven fan can be used to provide cooling air.

A 0 to 30 inch Hg (mercury) vacuum gauge should be connected to the suction side of the gear pump. The reading on the gauge should be less than 10 inches Hg when the oil temperature is above 120o F. Do not operate the Omega pump at full power during cold weather until the reading drops to below 20 inches Hg.

The discharge pressure gauge should have a pressure range from 0 to 150 PSI. Normal operating range will be from 60 to 100 PSI at oil temperatures from 100o F to 150o F. A separate oil pressure shutdown switch should be installed on the end of the lubrication pipe located through the power frame. The recommended shut-down setting is 30 PSI (falling pressure).

A combination temperature gauge and shut-down switch gauge should be installed on the sump/reservoir. The shut-down temperature should be set based on ambient temperature; 160o F (if ambient temperature is less than or equal to 80o F) and 170o F (if ambient temperature is greater than 80o F ). Gauges should either immediately shut equipment off or give adequate alarm warning followed by delayed equipment shut off.

WARNING

Hot oil can cause serious burns and disfigurement. Allow oil and components to cool to 130o F before performing either troubleshooting or service work. Keep gauges in good working order.

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Cold operating conditions may require the installation of a sump heater to prepare or keep the oil warm for normal starting operations. A 3000-watt immersion heater, with thermostat set at 80o F, is recommended.

4.16 PACKING LUBRICATION

Packing requires lubrication with lubricant as specified in Table 1 on page 6.

Fig. 15 shows an air-powered packing lubrication system. The equipment includes an air supply (usually an air compressor, governor and tank), a filter regulator, air hose, gauges, check valve, 3-way valve, "air over oil" reservoir, hydraulic hose, pipe fittings, oil check valves over each stuffing box, and finally the stuffing boxes and packing.

Pumps powered by diesel engines often will include an air-shifted transmission which will require an air compressor, governor and tank. The air tank can then be connected to the "air over oil" reservoir with necessary hoses and valves. Tank should have a valve at bottom for draining water.

The governor should be set to shift the air compressor into neutral when the pressure reaches 100 to 125 psi. A check valve is required between the compressor and tank to prevent back flow of air when the compressor is in neutral. The filter regulator should be set at 30 to 40 PSI for proper packing lubrication. The 3-way valve allows venting of the system as well as shut-off for maintenance.

The "air over oil" reservoir and filter-regulator is covered by a separate manual. The filter-regulator has an adjusting knob on its top to regulate pressure.

Drawing 1-50342 in the Appendix shows the components for the plunger lubrication system offered as an option on Omega pumps. Check valves are installed over each stuffing box to prevent flow of high pressure pumpage if packing failure were to occur. One-wire, 1/4" diameter hose should be used to connect the reservoir to the pipe cross over the middle stuffing box and to connect the cross to the other two stuffing boxes.

Packings can also be lubricated by a positive displacement metering pump powered by either a belt drive off the reciprocating pump crankshaft or an independent motor.

5.0 FASTENER TORQUES

Refer to the parts list drawings in Appendix for the item number locations.

Item Thread Type Torque No. Size - Pitch (ft-lbs) 06H 1"-8 Nut, Rod Hsg 350 150 3/4"-10 Nut, Rod Brg 180 226 1-1/4" 7 CS, Conn Rod 750 556 3/4"-10 CS, Brg Hsg 180 561 1-1/4"-7 CS, Bull Gear 900 598 1/2"-13 CS, Thst Seat 50 652 7/8"-9 CS, S. Mfld 250 675 1"-8 Nut, D. Flg 450 747 1/2"-13 CS, Rod Clamp 50 912 1-3/4"-8 Stay Rod 1000 913 1-3/4"-8 Nut, Stay Rod 2600

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OMEGA W1300 TRIPLEX PUMP CRITICAL DIMENSIONS & CLEARANCES Min./Max. New Condition Allowable Crankshaft diameter at main journals 16.002/16.001 16.000 Crankshaft diameter at rod journals 7.251/7.249 7.247 Crankshaft gear fit 7.000/6.999 6.997 Crankshaft keyway, width x depth 1.250 x 0.625 Crosshead slide bore diameter, in power frame 10.501/10.499 Same Crosshead diameter 9.858/9.856 9.852 Crosshead bore diameter, for wrist pin 2.502/2.501 2.504 Crosshead slide outside diameter 10.505/10.502 Same Crosshead slide inside diameter 9.878/9.876 9.882 Crosshead clearance, with crosshead slide 0.009/0.011 0.020 Wiper box oil seal runout 0.002/0.006 0.010 Wrist pin bushing outside diameter 3.003/3.001 Same Wrist pin bushing inside diameter 2.506/2.504 2.508 Wrist pin diameter 2.500/2.498 2.496 Pony rod diameter 4.877/4.875 4.872 Wrist pin bushing bore diameter, in connecting rod 3.000/2.999 Same Connecting rod bearing bore diameter 8.996/8.994 8.998 Connecting rod bearing clearance, to a side 0.001/0.005 0.007 Pinion bearing housing inside diameter 10.632/10.631 Same Pinion bearing housing outside diameter 12.504/12.502 Same Cylindrical bearing bore diameter, power frame 19.752/19.750 Same Cylindrical bearing outside diameter 19.750/19.748 Same Cylindrical bearing inside diameter 16.0000/15.9982 Same Cylindrical bearing width 3.000/2.995 Same Pinion bearing outside diameter 10.6299/10.6159 Same Pinion bearing inside diameter 5.9055/5.9045 Same Pinion bearing width 2.874/2.864 Same Pinion shaft diameter, at pinion bearing 4.250/4.249 4.247 Pinion output shaft diameter 4.000/3.999 3.997 Pinion shaft drive connection, width x depth 1.000 x 0.500 Stay rod length, shoulder-to-shoulder 13.001/12.999 12.997 OMEGA W1800 TRIPLEX PUMP CRITICAL DIMENSIONS & CLEARANCES Min./Max. New Condition Allowable Pinion bearing housing inside diameter 11.025/11.024 Same Pinion bearing outside diameter 11.0236/11.0226 Same Pinion bearing inside diameter 7.0866/7.0856 Same Pinion bearing width 3.937/3.927 Same Pinion shaft diameter, at pinion bearing 4.250/4.249 4.247 Pinion shaft drive connection 29 Tooth Spline All other dimensions same as W1300 above

24

OMEGA W2000 TRIPLEX PUMP CRITICAL DIMENSIONS & CLEARANCES Min./Max. New Condition Allowable Crankshaft diameter at main journals 16.002/16.001 16.000 Crankshaft diameter at rod journals 7.251/7.249 7.247 Crankshaft gear fit 7.000/6.999 6.997 Crankshaft keyway, width x depth 1.250 x 0.625 Crosshead slide bore diameter, in power frame 10.501/10.499 Same Crosshead diameter 9.858/9.856 9.852 Crosshead bore diameter, for wrist pin bushing 6.002/6.001 6.004 Crosshead slide outside diameter 10.505/10.502 Same Crosshead slide inside diameter 9.878/9.876 9.882 Crosshead clearance, with crosshead slide 0.009/0.011 0.020 Wiper box oil seal runout 0.002/0.006 0.010 Wrist pin bushing outside diameter 6.009/6.007 Same Wrist pin bushing inside diameter 5.262/5.261 5.264 Wrist pin diameter 5.250/5.249 5.247 Pony rod diameter 4.877/4.875 4.872 Connecting rod bearing bore diameter 8.996/8.994 8.998 Connecting rod bearing clearance, to a side 0.001/0.005 0.007 Pinion bearing housing inside diameter 11.025/11.024 Same Pinion bearing housing outside diameter 12.504/12.502 Same Cylindrical bearing bore diameter, power frame 19.752/19.750 Same Cylindrical bearing outside diameter 19.750/19.748 Same Cylindrical bearing inside diameter 16.0000/15.9982 Same Cylindrical bearing width 3.000/2.995 Same Pinion bearing outside diameter 11.0236/11.0226 Same Pinion bearing inside diameter 7.0866/7.0856 Same Pinion bearing width 3.937/3.927 Same Pinion shaft diameter, at pinion bearing 4.250/4.249 4.247 Pinion shaft drive connection 29 Tooth Spline Stay rod length, shoulder-to-shoulder 13.001/12.999 12.997

25

LOCATING TROUBLE TROUBLE POSSIBLE CAUSE REMEDY Pump vibrates or pounds. Gas in liquid. Submerge return, supply or

make-up lines in suction supply tank.

Pump valve stuck open. Stop. Remove debris beneath valve.

Pump not filling. Increase suction pressure. One or more cylinders not pumping. Stop. Prime all cylinders. Excessive pump speed. Reduce. Worn valve or seats. Replace or reface. Broken or missing springs. Replace. Loose or worn bearings. Tighten or replace. Worn crossheads. Replace. Loose wrist pin or crank.

Loose connecting rod cap bolts. Replace or adjust. Check tolerances.

Water in power end crankcase. Drain. Refill with clean oil Consistent knock. Worn or loose main bearing,

crank pin bearing, wrist pin bushing, piston and/or valve seat.

Replace or adjust. Check oil level in crankcase. Level may be too low or water may have worked in through the wiper boxes.

Excessive heat in power end.

Oil in crankcase. Check level, quality, contamination, etc.

Normal operating temperature from ambient to approximately 180o F maximum.

Overloaded. Check conditions of service. Pump crankshaft turning backwards. Check arrow on pump or on

elevation drawing. Poor lubrication. Check power end lubrication

system. Oil cooler malfunction Repair or replace oil cooler. Gauge malfunction Replace temp. switch gage. Scored parts (crossheads, connecting

rod bearings) Inspect and replace if necessary.

26

LOCATING TROUBLE TROUBLE POSSIBLE CAUSE REMEDY Pump fails to deliver required capacity.

Speed incorrect. Check with tachometer.

Air leaking into pump. Check all joints. Hydrotest. Replace o-rings.

Fluid cylinder valves, seats or plunger packing worn.

Replace valves and seats. Replace packing or plungers.

Not enough suction pressure above vapor pressure.

Increase static head or use a booster pump.

Pump not filling. Prime pump. Capacity of booster pump less than displacement of pump. Vortex in supply tank.

One or more cylinders not pumping. Stop. Prime all cylinders. Fluid valve stuck open. Stop. Remove debris beneath

valve. Clogged suction strainer. Clean or remove. Relief or bypass valves leaking. Check and repair. Low volumetric efficiency. Liquid with low specific gravity

or high discharge pressure compressing and expanding in pump. Worn valves or seats. Air in fluid.

Suction and/or discharge piping vibrates or pounds.

Piping too small and/or too long. Too many elbows.

Increase size and decrease length. Use booster pump. Use suction and/or discharge pulsation dampeners. (See Sec. 4.5)

Worn valve or seats. Replace.

Wear of fluid end parts (excessive).

Abrasive or corrosive action of the fluid.

Check valves and seats frequently at start-up to determine schedule for replacement. Eliminate sand, abrasives, or air entering pump. Flush pump after use with acids.

Broken valve springs. Replace. Bypassing to suction. Replace worn parts. Incorrect material. Check with pump manufacturer.

27

LOCATING TROUBLE TROUBLE PROBABLE CAUSE REMEDY Wear of valve parts (excessive)

Corrosion. Treat fluid if possible.

Abrasives in fluid. Filter if possible. Valve spring malfunction. Check spring tension.

Replace if necessary. Improper valve seating. Replace seat if worn or

damaged. Pump not filling. Increase suction pressure.

Prime all cylinders. Damaged o-rings or inserts. Replace. Pulsation dampeners malfunctioning. Charge correctly. Repair.

Short Plunger or Packing Life

Improper installation. Inspect and install per drawing and instructions.

Loose gland nut. Inspect threads. Tighten. Particulate build-up on plungers. Treat fluid. Use rock drill oil to

cut away build-up. Worn or pitted plungers. Replace. Abrasives in fluid. Filter as required. High wear, friction. Lubricate with rock drill oil. Packing bore washout. Repair to original tolerance.

Replace packing.

Wear of power end parts (excessive).

Poor lubrication. Check. Replace oil as recommended in instructions. Examine for water, sand, dirt, paint, etc. Be sure oil is reaching all bearings. Check power lubricator system.

Overloading. Check operating conditions against conditions of service on original order. If operating conditions greater, check with pump manufacturer.

Fluid entry into power end. Stop. Replace packing and parts affected. Continued operation with excessive leaking rod packing will ultimately allow entry of fluid into power end.

28

LOCATING TROUBLE TROUBLE PROBABLE CAUSE REMEDY Low Oil Pressure on Power End Lubrication System

Worn gear pump. Replace pump.

Faulty relief valve. Replace relief valve. Damaged gauge. Replace gauge.

High Oil Pressure on Power End Lubrication System

Cold oil. Add sump heater, warm-up equipment.

Clogged filter. Change element. Blocked line. Break connections, find

blockage and remove. Too much flow. Reduce gear pump speed.

Use gear pump with smaller displacement.

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APPENDIX

TABLE 3-1 RECOMMENDED LUBRICATION OILS

OIL COMPANY BRAND NAME OF OIL Oils Recommended for General Service Shell Spirax HD 90 Texaco Meropa 220 Exxon Spartan EP 220 Gulf EP Lubricant S-100

nsgear EP 90 Mobil Mobilube HD 90 Atlantic-Richfield Rennant NL S-1000

co HD Gear Oil 90 Cities Services Citgo EP Compound 90

ra Duty Circulating Oil, Grade 85 Amoco Amoco MP Gear Lube #90 Sun Oil Company Sunep 1070 Standard Oil (Chevron) NL Gear Compound 220 Pennzoil Maxol EP Gear Oil #3 Oils Recommended for Extreme Warm-Weather Service Shell Sprax HD 140 Texaco Meropa 460 Exxon Spartan EP 460 Mobil Mobilube HD 140

bilube SHC 634* Chevron NL Gear Compound 460 Amoco Amoco EP Grand 5

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APPENDIX

TABLE 3-1 RECOMMENDED LUBRICATION OILS

OIL COMPANY BRAND NAME OF OIL Oils Recommended for Extreme Cold-Weather Service Shell Sprax HD 80 Texaco Multigear EP 80W Exxon Gear Oil GX 80 Mobil Mobilube SHC 626* Standard Oil (Chevron) Universal Gear Lubricant 80W 90 Conoco ND 600 Gear Oil

* These are synthesized hydrocarbon lubes and are relatively expensive. They do provide excellent lubrication under adverse conditions.

31

NOI - OMEGA W2250

4 " TO 7-1/2 " X 8 " Rod Load = 250,000 LBS.

PLUNGER DISPLACEMENTFACTORS

DIAMETER @ 100% V.E. 100 150 200 250 330CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE

(1) PRESSURE PRESSURE PRESSURE PRESSURE PRESSUREU.S. GAL. U.S. GAL. MAXIMUM U.S. GAL. MAXIMUM U.S. GAL. MAXIMUM U.S. GAL. MAXIMUM U.S. GAL. MAXIMUM

per per @ CAPACITY per @ CAPACITY per @ CAPACITY per @ CAPACITY per @ CAPACITYREV. MIN. (2) MIN. MIN. MIN. MIN.

Inches GPR GPM PSIG GPM PSIG GPM PSIG GPM PSIG GPM PSIG 7.50 4.590 459 5650 689 4761 918 3571 1148 2857 1515 21647.00 3.998 400 6486 600 5466 800 4100 1000 3280 1319 24856.75 3.718 372 6975 558 5878 744 4408 930 3527 1227 26726.50 3.448 345 7521 517 6338 690 4754 862 3803 1138 28816.00 2.938 294 8827 441 7438 588 5579 735 4463 970 33815.75 2.698 270 9612 405 8100 540 6075 675 4860 890 36825.50 2.468 247 10508 370 8855 494 6641 617 5313 814 40255.00 2.040 204 12712 306 10713 408 8034 510 6428 673 48694.50 1.652 165 15698 248 13229 330 9921 413 7937 545 60134.00 1.306 131 19857 196 16733 261 12550 327 10040 431 7606

INPUT BHP 1780 2250 2250 2250 2250POWER

@ 85% ME KW 1327 1678 1678 1678 1678

@ 6.35:1 GEAR RATIO 635 953 1270 1588 2096

(1) - BASED ON 100% VOLUMETRIC EFFICIENCY.(2) - OPERATION AT PRESSURES ABOVE 15,000 PSIG MUST BE APPROVED BY "NOI" ENGINEERING - OMEGA PUMPS.(3) - INPUT POWER BASED ON 85% MECHANICAL EFFICIENCY.

PINION SPEED

My Documents\Excel\Omega\Performance Charts\W2250 Rev A.xls

OMEGA PARTS LIST FOR MODEL W1800, W2000

POWER END ASSEMBLY

ITEM PART NUMBER QTY PART DESCRIPTION NO. _____________ ___ _____________________ 001 008-050864-231 1 POWER FRAME 014 001-011094-999 1 BREATHER CAP 019 002-050026-302 3 CROSSHEAD SLEEVE 038 AAB-051591-282 1 TOP COVER 048 002-050264-282 1 REAR COVER 050 100-038034-290 56 CAP SCREW *055 147-516012-220 4 DOWEL PIN 105 AAC-051392-220 1 CRANKSHAFT 125 121-160198-999 4 CRANKSHAFT BEARING 209 324-058034-220 3 SET SCREW 210 324-058200-220 3 SET SCREW 211 001-050022-302 3 WRIST PIN BUSHING 212 004-050418-359 3 CROSSHEAD 213 001-050021-236 3 WRIST PIN 216 001-050027-231 3 WIPER BOX 217 002-050365-204 3 GASKET 218 100-058114-290 18 CAP SCREW *266 126-006516-405 4 DRIVE SCREW *267 AAA-051644-405 1 NAMEPLATE 509 177-001648-999 8 SNAP RING 510 177-002008-999 4 SNAP RING 516 145-478600-998 3 OIL SEAL, WIPER BOX 521 001-050076-275 2 LUBRICATION ADAPTER 524 110-000223-200 2 O-RING 528 272-516034-220 8 CAP SCREW 541 AAC-051579-476 3 CONNECTING ROD 542 AAC-051793-999 3 CON ROD BRG HOUSING 544 AAB-051377-306 3 CON ROD BEARING 545 AAB-051378-306 3 CON ROD BEARING 546 109-100300-290 12 CAP SCREW 548 104-034312-286 18 STUD 549 150-034010-286 18 NUT 551 004-050520-220 1 BULL GEAR,LH,6.35:1 RATIO 552 004-050519-220 1 BULL GEAR,RH,6.35:1 RATIO 553 004-050518-220 1 PINION SHAFT,6.35:1 RATIO 554 255-708110-999 2 BEARING 555 002-050278-231 2 BEARING HOUSING 556 442-034112-290 6 CAP SCREW 557 442-034200-290 6 CAP SCREW 561 442-114300-290 8 CAP SCREW 562 153-114194-220 8 LOCK WASHER 563 001-050032-302 2 THRUST RING 564 188-038034-306 16 CAP SCREW, FLAT HEAD 565 002-050364-236 2 KEY 566 324-012012-220 2 SET SCREW 567 324-012034-220 2 SET SCREW 570 004-050444-282 1 GEAR COVER, LH 571 004-050522-282 1 GEAR COVER, RH 572 AAA-051992-999 50 GASKET 573 100-038034-290 84 CAP SCREW 577 AAA-050009-282 8 INSPECTION COVER 578 002-050367-204 8 GASKET 579 100-038034-290 32 CAP SCREW

ITEM PART NUMBER QTY PART DESCRIPTION NO. _____________ ___ ________________________ 580 998-231000-015 1 LUBRICATION ASSEMBLY LUBRICATION ASSEMBLY INCLUDES THE FOLLOWING PARTS: 02L 157-100300-551 4 PIPE NIPPLE 03L 367-100403-353 4 REDUCING TEE 04L 170-100002-220 2 PIPE PLUG 05L 001-050360-999 2 HOSE 06L 001-050649-999 2 ROTARY UNION 07L 161-012014-353 2 REDUCER BUSHING 08L 002-050382-003 2 HOSE 09L 001-050052-551 2 FEED TUBE 10L 002-050382-001 3 HOSE 11L 470-040404-305 3 HOSE ADAPTER 12L 002-050382-004 4 HOSE 13L 168-014030-353 4 ELBOW, 45 14L 157-014200-551 4 PIPE NIPPLE 15L 470-010810-305 1 HOSE ADAPTER 16L 470-010404-305 4 HOSE ADAPTER 583 AAB-052041-220 1 DRIP PAN *584 100-038034-290 4 CAP SCREW 585 145-134213-999 2 OIL SEAL 586 001-050075-275 2 SEAL RETAINER 587 002-050366-204 2 GASKET 588 100-038114-290 6 CAP SCREW 589 145-414513-999 1 OIL SEAL 590 001-050060-231 1 SEAL RETAINER 591 002-050369-204 2 GASKET 592 100-038114-290 6 CAP SCREW 593 002-050232-400 3 PONY ROD 594 109-034112-290 18 CAP SCREW 595 001-050656-220 90 LOCK WIRE 596 001-050019-301 3 THRUST SEAT 597 001-050023-231 6 RETAINER 598 109-012114-290 24 CAP SCREW 912 AAB-051499-274 12 STAY ROD 913 184-134008-286 12 NUT OPTIONAL PARTS AND KITS SUMP KIT 006 AAC-051362-220 1 SUMP 007 AAA-051502-201 1 O-RING 008 100-038078-290 30 CAP SCREW 010 170-100001-220 1 PLUG * ~ NOT SHOWN ON PARTS DRAWING NOTE: WHEN ORDERING PARTS, GIVE 1) PUMP SERIAL NUMBER 2) PUMP MODEL NUMBER 3) PART NUMBER 4) QUANTITY 5) PART DESCRIPTION 6) ITEM NUMBER

REVISION DATE: April 12, 2001 REVISION PCN: 7892 A-051527 REV. D

OMEGA PARTS LIST FOR MODEL W1300 W2250

3.75 FLUID END ASSEMBLY

ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE 600 AAC-051692-487 1 FLUID END, AUTOFR 625 AAB-051693-274 3 VALVE COVER 626 110-000425-200 6 O-RING 627 459-000425-999 3 BACK-UP RING 630 AAB-050070-274 6 RETAINER NUT 640 AAB-051051-274 3 CYLINDER HEAD 641 110-000427-200 6 O-RING 646 459-000427-999 3 BACK-UP RING 649 AAC-051356-236 3 CAGE 650 AAC-050886-220 1 SUCTION MANIFOLD 651 110-000258-200 3 O-RING 652 100-078112-290 12 CAP SCREW 674 104-100314-286 12 STUD 675 133-100008-286 12 NUT 697 AAB-051347-274 3 GLAND NUT 703 998-BRS334-012 3 BRASS SET 713 AGB-051289-999 3 WIPER SEAL 735 AAB-051366-999 3 COLMONOY PLGR., 16 L 746 AAC-050478-241 3 PUSH ROD CLAMP w/CAP SCREWS 747 105-012112-290 6 CAP SCREWS 860 AAB-051363-236 3 SPRING RETAINER STYLE 1067 PACKING SETS 733 001-051025-028 3 PACKING SET EACH SET CONSIST OF THE FOLLOWING: 7331 001-050894-004 2 PACKING RING 7332 001-050895-004 1 HEADER RING MISSION VALVE ASSEMBLIES 865 998-W20000-152 6 VALVE ASSEMBLY EACH ASSY CONSISTS OF THE FOLLOWING: 866 080130297 1 SEAT w/O-RING 867 110-000238-200 1 O-RING 868 070113303 1 BODY w/INSERT 870 072442023 1 INSERT 871 002-050357-999 1 SPRING

ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE DISCHARGE FLANGE OPTIONAL PARTS 671 AAB-051396-274 1 2" 1502 FEMALE FLANGE 671 AAB-051398-274 1 3" 1502 FEMALE FLANGE *671 AAB-051639-999 1 3 1502 MALE FLANGE 672 AAB-051395-274 1 BLIND w/BLEED-OFF PORT 672 AAB-051477-274 1 BLIND FLANGE 673 110-000338-220 2 O-RING OPTIONAL FLUID END PARTS 633 AAB-050028-274 1 RETAINER NUT GAUGE CONNECTION 636 AAB-051694-274 1 VALVE COVER w/GAUGE CONNECTION 735 AAB-051510-E21 1 3.75 PLUNGER x 18 LONG OPTIONAL TOOLS 637 001-059021-220 1 2" HEX WRENCH 648 002-050229-220 1 SLIDE HAMMER COVER PULLER 682 AAC-051496-220 1 VALVE LIFTER 693 AAB-051293-274 1 SPANNER WRENCH 890 001-050897-999 1 VALVE SEAT PULLER ASS'Y (DOES NOT INCLUDE PULLER HEAD) 8909 AAB-051047-220 1 PULLER HEAD VALVE SEAT PULLER ASSEMBLY COMPONENTS 8901 001-050897-001 1 HAND PUMP 8902 001-050897-002 1 HOSE 8903 001-050897-003 1 HOSE ADAPTER 8904 001-050897-004 1 HYDRAULIC JACK 8905 001-050897-005 1 METAL BOX 8907 001-059014-236 1 PULL ROD 8908 133-200412-286 1 HEX NUT

* ~ NOT SHOWN ON PARTS DRAWING NOTE:WHEN ORDERING PARTS, GIVE 1) PUMP SERIAL NUMBER 2) PUMP MODEL NUMBER 3) PART NUMBER 4) QUANTITY 5) PART DESCRIPTION 6) ITEM NUMBER

Revision Date: January 20, 2003 REVISION PCN 8121 A-052291 Rev. A



ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE 600 AAC-051538-487 1 FLUID END, AUTOFR 625 AAB-051693-274 3 VALVE COVER 626 110-000425-200 6 O-RING 627 459-000425-999 3 BACK-UP RING 630 AAB-050070-274 6 RETAINER NUT 640 AAB-051051-274 3 CYLINDER HEAD 641 110-000427-200 6 O-RING 646 459-000427-999 3 BACK-UP RING 649 AAC-051356-236 3 CAGE 650 AAC-050886-220 1 SUCTION MANIFOLD 651 110-000258-200 3 O-RING 652 100-078112-290 12 CAP SCREW 674 104-100314-286 12 STUD 675 133-100008-286 12 NUT 697 002-050981-274 3 GLAND NUT 703 998-BRS400-012 3 BRASS SET 711 110-000256-200 3 O-RING 713 AHB-051289-999 3 WIPER SEAL 735 002-050217-999 3 COLMONOY PLGR., 16 L 746 AAC-050478-241 3 PUSH ROD CLAMP w/CAP SCREWS 747 105-012112-290 6 CAP SCREWS 860 AAB-051363-236 3 SPRING RETAINER STYLE 1067 PACKING SETS 733 001-051025-005 3 PACKING SET EACH SET CONSIST OF THE FOLLOWING: 7331 001-050894-005 2 PACKING RING 7332 001-050895-005 1 HEADER RING MISSION VALVE ASSEMBLIES 865 998-W20000-152 6 VALVE ASSEMBLY EACH ASSY CONSISTS OF THE FOLLOWING: 866 080130297 1 SEAT w/O-RING 867 110-000238-200 1 O-RING 868 070113303 1 BODY w/INSERT 870 072442023 1 INSERT 871 002-050357-999 1 SPRING

ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE DISCHARGE FLANGE OPTIONAL PARTS 671 AAB-051396-274 1 2" 1502 FEMALE FLANGE 671 AAB-051398-274 1 3" 1502 FEMALE FLANGE *671 AAB-051639-999 1 3 1502 MALE FLANGE 672 AAB-051395-274 1 BLIND w/BLEED-OFF PORT 672 AAB-051477-274 1 BLIND FLANGE 673 110-000338-220 2 O-RING OPTIONAL FLUID END PARTS 633 AAB-050028-274 1 RETAINER NUT GAUGE CONNECTION 636 AAB-051694-274 1 VALVE COVER w/GAUGE CONNECTION 735 AAB-051511-999 1 4 PLUNGER x 18 LONG OPTIONAL TOOLS 637 001-059021-220 1 2" HEX WRENCH 648 002-050229-220 1 SLIDE HAMMER COVER PULLER 682 AAC-051496-220 1 VALVE LIFTER 693 AAB-051293-274 1 SPANNER WRENCH 890 001-050897-999 1 VALVE SEAT PULLER ASS'Y (DOES NOT INCLUDE PULLER HEAD) 8909 AAB-051047-220 1 PULLER HEAD VALVE SEAT PULLER ASSEMBLY COMPONENTS 8901 001-050897-001 1 HAND PUMP 8902 001-050897-002 1 HOSE 8903 001-050897-003 1 HOSE ADAPTER 8904 001-050897-004 1 HYDRAULIC JACK 8905 001-050897-005 1 METAL BOX 8907 001-059014-236 1 PULL ROD 8908 133-200412-286 1 HEX NUT


Revision Date: January 20, 2003 REVISION PCN 8121 A-051695 Rev. E



ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE 600 AAC-051623-487 1 FLUID END, AUTOFR 625 AAB-050944-274 3 VALVE COVER 626 110-000427-200 6 O-RING 627 459-000427-999 3 BACK-UP RING 630 AAB-050070-274 3 RETAINER NUT 640 AAB-050946-274 3 CYLINDER HEAD 641 110-000432-200 6 O-RING 643 AAB-051067-274 3 RETAINER NUT 646 459-000432-999 3 BACK-UP RING 649 004-050916-236 3 CAGE 650 AAC-050886-220 1 SUCTION MANIFOLD 651 110-000258-200 3 O-RING 652 100-078112-290 12 CAP SCREW 674 104-100314-286 12 STUD 675 133-100008-286 12 NUT 697 004-059837-274 3 GLAND NUT 703 998-BRS412-012 3 BRASS SET 711 110-000259-200 3 O-RING 713 AKB-051289-999 3 WIPER SEAL 735 002-050224-999 3 COLMONOY PLUNGER 746 AAC-050476-241 3 PUSH ROD CLAMP w/CAP SCREWS 747 105-012112-290 6 CAP SCREWS 860 002-050913-274 3 SPRING RETAINER STYLE 1067 PACKING SETS 733 001-051025-006 3 PACKING SET EACH SET CONSIST OF THE FOLLOWING: 7331 001-050894-014 2 PACKING RING 7332 001-050895-014 1 HEADER RING MISSION VALVE ASSEMBLIES 865 998-231013-075 6 VALVE ASSEMBLY EACH ASSY CONSISTS OF THE FOLLOWING: 866 080120504 1 SEAT w/O-RING 867 110-000245-200 1 O-RING 868 070113352 1 BODY w/INSERT 870 072442155 1 INSERT 871 AAA-051092-999 1 SPRING

ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE DISCHARGE FLANGE OPTIONAL PARTS 671 AAB-051396-274 1 2" 1502 FEMALE FLANGE 671 AAB-051398-274 1 3" 1502 FEMALE FLANGE *671 AAB-051639-999 1 3 1502 MALE FLANGE 672 AAB-051395-274 1 BLIND w/BLEED-OFF PORT 672 AAB-051477-274 1 BLIND FLANGE 673 110-000338-220 2 O-RING OPTIONAL FLUID END PARTS 633 AAB-050028-274 1 RETAINER NUT GAUGE CONN. 735 AAB-051512-999 3 4-1/2 X 18L PLUNGER 636 AAB-050417-274 1 VALVE COVER w/GAUGE CONN. OPTIONAL TOOLS 637 001-059021-220 1 2" HEX WRENCH 648 002-050229-220 1 SLIDE HAMMER COVER PULLER 682 AAC-051496-220 1 VALVE LIFTER 693 AAB-051293-274 1 SPANNER WRENCH 890 001-050897-999 1 VALVE SEAT PULLER ASS'Y (DOES NOT INCLUDE PULLER HEAD) 8909 AAB-051047-220 1 PULLER HEAD VALVE SEAT PULLER ASSEMBLY COMPONENTS 8901 001-050897-001 1 HAND PUMP 8902 001-050897-002 1 HOSE 8903 001-050897-003 1 HOSE ADAPTER 8904 001-050897-004 1 HYDRAULIC JACK 8905 001-050897-005 1 METAL BOX 8907 001-059014-236 1 PULL ROD 8908 133-200412-286 1 HEX NUT


Revision Date: January 20, 2003 REVISION PCN 8121 A-051503 Rev. D



ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE 600 AAC-051085-487 1 FLUID END, AUTOFR 625 AAB-050944-274 3 VALVE COVER 626 110-000427-200 6 O-RING 627 459-000427-999 3 BACK-UP RING 630 AAB-050070-274 3 RETAINER NUT 640 AAB-050911-274 3 CYLINDER HEAD 641 110-000435-200 6 O-RING 643 AAA-051073-274 3 RETAINER NUT 646 459-000435-999 3 BACK-UP RING 649 004-059838-236 3 CAGE 650 AAC-050886-220 1 SUCTION MANIFOLD 651 110-000258-200 3 O-RING 652 100-078112-290 12 CAP SCREW 674 104-100314-286 12 STUD 675 133-100008-286 12 NUT 697 004-050926-274 3 GLAND NUT 703 998-BRS500-012 3 BRASS SET 711 110-000261-200 3 O-RING 713 AMB-051289-999 3 WIPER SEAL 735 002-050325-999 3 COLMONOY PLUNGER 746 AAC-050477-241 3 PUSH ROD CLAMP w/CAP SCREWS 747 105-012112-290 6 CAP SCREWS 860 002-050913-274 3 SPRING RETAINER STYLE 1067 PACKING SETS 733 001-051025-008 3 PACKING SET EACH SET CONSIST OF THE FOLLOWING ITEMS: 7331 001-050894-009 2 PACKING RING 7332 001-050895-009 1 HEADER RING MISSION VALVE ASSEMBLIES 865 998-231013-075 6 VALVE ASSEMBLY EACH ASSY CONSISTS OF THE FOLLOWING: 866 080120504 1 SEAT w/O-RING 867 110-000245-200 1 O-RING 868 070113352 1 BODY w/INSERT 870 072442155 1 INSERT 871 AAA-051092-999 1 SPRING

ITEM NO PART NUMBER QTY PART DESCRIPTION/SIZE DISCHARGE FLANGE OPTIONAL PARTS 671 AAB-051396-274 1 2" 1502 FEMALE FLANGE 671 AAB-051398-274 1 3" 1502 FEMALE FLANGE *671 AAB-051639-999 1 3 1502 MALE FLANGE 672 AAB-051395-274 1 BLIND w/BLEED-OFF PORT 672 AAB-051477-274 1 BLIND FLANGE 673 110-000338-220 2 O-RING OPTIONAL FLUID END PARTS 633 AAB-050028-274 1 RETAINER NUT GAUGE CONNECTION 735 AAB-051513-999 3 5 x 18 LONG PLUNGER 636 AAB-050417-274 1 VALVE COVER w/GAUGE CONNECTION OPTIONAL TOOLS 637 001-059021-220 1 2" HEX WRENCH 648 002-050229-220 1 SLIDE HAMMER COVER PULLER 682 AAC-051496-220 1 VALVE LIFTER 693 AAB-051293-274 1 SPANNER WRENCH 890 001-050897-999 1 VALVE SEAT PULLER ASS'Y (DOES NOT INCLUDE PULLER HEAD) 8909 AAB-051047-220 1 PULLER HEAD VALVE SEAT PULLER ASSEMBLY COMPONENTS 8901 001-050897-001 1 HAND PUMP 8902 001-050897-002 1 HOSE 8903 001-050897-003 1 HOSE ADAPTER 8904 001-050897-004 1 HYDRAULIC JACK 8905 001-050897-005 1 METAL BOX 8907 001-059014-236 1 PULL ROD 8908 133-200412-286 1 HEX NUT * ~ NOT SHOWN ON PARTS DRAWING NOTE: WHEN ORDERING PARTS, GIVE 1) PUMP SERIAL NUMBER 2) PUMP MODEL NUMBER 3) PART NUMBER 4) QUAN