W600S OMEGA

OPERATION MAINTENANCE MANUAL

 INSTALLATION PROCEDURE
1.0 INTRODUCTION

National Oilwell 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 other
factory facilities are ready to help you. Feel free to contact us for assistance.

To improve our products we must be informed of the problems and solutions that 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, if any. Forward to National
Oilwell, Omega Pump Products Attention: Engineering, P.O. Box 2069, Tulsa, OK 74101-2069.
Your help will be greatly appreciated.

2.0 PARTS AND SERVICE

National Oilwell 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 Parts List in Appendix).
2. Quantity of each part required.
3. Fluid end/power end model and serial number.
4. 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.

3.0 GENERAL

National Oilwell pumps, when properly installed, given proper 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.

3.1 Storage
All National Oilwell pumps are tested, inspected and protected against corrosion for the
period of shipment and installation only. If the pump is not to be installed at once, refer
to the section entitled "Long Term Storage of Pumps".

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, so as to make
suction piping short and direct. Provide ample headroom 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 Servicing Space

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

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 INSTALLATION PROCEDURE

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 Couplings
On pumps where couplings are used, do not connect the coupling until all pump and
driver alignment operations have been completed. Check the coupling faces and flanges
of the pump for true horizontal and vertical position by means of a level. Correct the
positions by adjusting the supports as required.

3.7 Drive Shaft

Both short-coupled and tube-type Splicer 1810 drive lines are used to couple the engine
clutch or transmission to the gearbox. Drive lines are flanged on each end for bolting to
mating flanges on the transmission or gearbox.

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 quality of EP grease meeting the NLG1
grade 2 specification. Grease every one to three months depending on service.

3.8 Gearbox
An enclosed gearbox with a 4.6:1 ratio is mounted on either the left or right side of the
power end. Provided the input shaft clears the pump housing, the gearbox is reversible.

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. Refer to
gearbox manual for specific recommendations.

Parts list and assembly of the gearboxes are included at the back of the manual in the
gearbox manual.

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

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 INSTALLATION PROCEDURE

4.0 PIPING

4.1 General
Pipes must line up naturally. They must NOT be forced into place with flange bolts, as
this may force the pump out of alignment. Pipes should be supported independently of
pump thereby not producing any strain.

Variations in flow and pressure, changes in direction of flow, cavitation, worn plungers,
pump valves, etc., all contribute to piping vibration. Therefore, suction and discharge
piping must be rigidly fixed in all directions and not just lightly strapped down. Flush,
clean and blowout all piping before connecting to pump. Use pipe dope and tape
sparingly, and on the male threads only.

After the piping is installed, the pump driver and speed reducer alignment should be
rechecked and corrected as required.

4.2 Suction Piping and Charge Pump

The pump suction piping should be direct, free of bends and restrictions, also, as short as
possible. All bends or turns required 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 pumps suction diameter.
The pipe should be routed without high spots, and have a continual rise upward toward
the pump. The pump must be able to be isolated for servicing; therefore, a fully opening
block 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 20 psi at the
reciprocating pump suction at maximum operating capacity.

To prevent mutually reinforcing pulsation in multiple pump installations, each pump

should be provided with a separate inlet line from the liquid source rather than connecting
two or more pumps to a common manifold. If manifolding is required, the manifold
and/or suction pipe should have a cross-sectional area equal to or greater than the sum of
the cross-sectional areas of the suction lines to each individual pump.

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 INSTALLATION PROCEDURE

4.3 Discharge Piping

The pump discharge piping should be direct, free of bends and restrictions, and as short
as possible. All bends or turns required should be either long radius or 45o elbows. All
"dead ends" should be avoided. The piping should be pressure tested.

Adequate provisions should be made for anchoring and supporting the piping spans. The
pump must be able to be isolated for servicing; therefore, a fully opening block valve
should be located in the discharge piping. Also, to protect the pump, a check valve
should be employed. To facilitate starting and to eliminate air, a vent or bypass valve
should be installed close to the pump.

4.4 Flange Fittings

Flange fittings, unions and flexible connectors should be located close to the pump in all
pipelines, so as to facilitate removal of pump.

Alignment must be rechecked after suction and discharge piping have been bolted to the
pump, to test the effect of piping strains. When handling hot or extremely cold liquids,
disconnect the nozzle flanges after the unit has been in service to check the direction in
which the piping expansion is acting. Correct for strain effect, as required, to obtain true
flange alignment.

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.

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 INSTALLATION PROCEDURE
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.

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 b 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 filters should be considered.

In systems that 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.

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 INSTALLATION PROCEDURE

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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 START-UP PROCEDURE

1.0 Verify pump has been properly installed and that related equipment is operational.

2.0 Open the suction line block valve and the discharge line vent or bypass. If the discharge line is
under pressure close the discharge line block valve to fill all lines and force air out of system.
Close vent (or bypass) valve. Open the discharge line block valve. Start pump driver and check
direction of crankshaft rotation against arrow on power frame. If driver is at three-phase electric
motor, rotation can be reversed by switching the connection of any two motor leads.

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 of 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. 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 over
on the power end to observe oil flow.

3. 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, pine
bearings, and gears for proper oiling.

4. Increase engine RPM to full RPM. Check the vacuum gage reading at the power end
lubrication pump suction. Reading should be less than 10 in 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.

5. Check oil reservoir level. Add oil if necessary.

6. Clean plungers at back of stuffing box. Squirt oil on plungers.

7. Reduce engine speed. Operate triplex pump at 70-80 RPM and no pressure for 1/2 hour.
Oil temperature should not climb above 140o F (60o C). Observe power end for leakage
an unusual noise. Lubrication pump vacuum gage reading should not fall below 10 in
HG (35 kPa). If it does, filters may be clogged; change as necessary. Discharge pressure
of lubrication pump should exceed 50 psi (3.4 bar).

8. 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 (82o C).

9. 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
10. 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.

If power end is too hot to touch, check temperature. If oil temperature is above 180O F
(82O C), stop pump and allow cooling to ambient temperature. Repeat break-in run. If oil
temperature continues to exceed 180O F (82O C), stop the pump and refer to "Locating
Trouble" in Maintenance Instructions.

4.0 The electric motors driving most pumps are capable of starting the pump against line pressure.
However, due to electrical supply considerations, it may be advisable to use a manual or
automatic bypass valve to unload the pump until it has reached operating speed.

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

POWER END LUBRICATION

Safe Viscosity Timken

Type of SUS @ Centi- Pour Point ISO AGMA
Ambient Temp. F Operating Rating
Service Stokes F Grade Grade
Temp. F 100o F 1 bl.
0-95 Up to 180
General 1165 252.00 10 (-12o C) 65.00 220.00 5 EP
(-18o C to 35o C) (82o C)
Above 95 Up to 200
Hot 1710 370.00 10 (-12o C) 65.00 320.00 6 EP
(35o C) (93o C)
Below 0 Up to 130
Cold 350 76 5 (-15o C) 60.00 68.00 2 EP
(-18o C) (54o C)
SSU=Centistokes *4.62

PACKING LUBRICATION

Liquid Pumped Ambient Temp. F Lubricant

Water, Saltwater Above 0 (-18o C) Rock Drill Oil 100

General Service Below 0 (-18o C) Rock Drill Oil 46

Petroleum Products Above 10o (38o C) Straight Mineral Oil

Any Below 20 (-29o C) Brake Fluid

Table 1: Lubrication Specifications

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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 nominal 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 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).

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.

Cradle area (clean and properly draining).

V-belts (not slipping) and/or drive couplings (for oil or grease leakage).

Fluid end operating pressures (not above specified nameplate values).

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

Pumps with power end pressure lubrication to be 40 PSIG (2.8 bar) minimum at normal
operating temperature.

Packing lubricator pumps (all functioning, proper drip rate).

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 MAINTENANCE INSTRUCTIONS

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).

IF THE PUMP IS NEW OR HAS RECEIVED A RECENT MAJOR OVER-HAUL

(SHELL BEARINGS, WRIST PINS, BUSHINGS, END BEARINGS, ETC.,) OIL
SHOULD BE CHANGED AT THIS INTERVAL. PRIOR TO ADDING NEW OIL,
CRANKCASE COVER SHOULD BE REMOVED AND ALL EXPOSED INTERIOR
SURFACES WIPED CLEAN. PRIOR TO CRANKCASE COVER REPLACEMENT,
CHECK TORQUE OF ALL CONNECTING ROD BOLTS. 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 or Every 750 Hours of Pump Operation

Crankcase breather screen (clear and free of debris).

Lubricator lines and connections (for leaks and crimps).

3.4 Quarterly or Every 2250 Hours of Pump Operation

Power end and, if applicable, gear reducer (change oil).

Oil filter element (clean in kerosene or replace).

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

3.5 Semi-Annual or Every 4500 Hours of Pump Operation

Drive couplings (lubricate and, if applicable, check seals and bolt torques).

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

Valve springs (broken or compressed).

Plungers and pony rods (scored, worn or damaged).

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

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 MAINTENANCE INSTRUCTIONS

3.6 Annual or Every 9,000 Hours of Pump Operation

Schedule disassembly and inspection of complete pump, concentrating especially on:

- Crankshaft throw/pin surfaces;
- Crankshaft end bearings & oil seals;
- Wrist pins and wrist pin bushings;
- Power end pressure lube pump internals and shimming (if applicable);
- Center main crankshaft journals and bearing bores (if applicable);
- Plungers and, pony rods;
- Wiper box seals and o-rings;
- Stuffing box packing, brass and springs (if applicable);
- Valve assemblies;
- Fluid end gaskets and seals;
- Speed reducer gears, bearings and shaft seals.

4.0 SERVICE PROCEDURES

4.1 Discharge Valves

The discharge valve is located just beneath the valve cover in the upper part of the fluid
end (see Fig. 1). Replacement of the spring or valve body can be accomplished without
removing the valve seats. If it is necessary to remove the discharge valve seat, remove
with valve seat puller available from National Oilwell (see Fig. 2). Be careful not to mar
the tapered deck-seating surface.

4.2 Suction Valves

The suction valve is accessible after removing the cylinder head retainer nut and cover.
To remove the suction valve seat, it is necessary to first remove the discharge valve. To
get the plunger out of the way, rotate the pump until the plunger reaches its full back
position. Stop it before beginning the forward stroke. The next step is to disassemble the
valve components from the valve seat. Seat removal is accomplished by the use of a
puller available from the factory.

Refer to Fig. 3 when installing valve seats. Take care to avoid damage of tapered deck-
seating surfaces.

Valve seats should be DRIVEN into the seat deck until firmly seated. This is done by
using a flat disc and driving with a piece of pipe and a hammer.

e CAUTION ^
Never drive on the valve body and do not use any method that will distort valve seats.
Taper surfaces must be CLEAN AND DRY! Use clean solvent or diesel fuel. Then wipe
dry with a clean rag before assembly.

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 MAINTENANCE INSTRUCTIONS

4.3 Plungers

Plungers are removed through the fluid cylinder bore as shown in Fig. 1. First, remove
the cylinder head retaining nut and cover. Using the spanner wrench, loosed the gland nut
one full turn. Unscrew each plunger from the crosshead and remove the plunger through
the fluid end.

Threaded holes on the cylinder head cover are for attaching a lifting bar to assist in
removal.

e CAUTION ^
Handle the plunger carefully. Any nicks in the main body of the plunger will cause
immediate and frequent packing failure.

008
105

006
105

007

105

105

009

010

008
033

028

105
011
004
105
105
005 105

105
031

105
032

030

105 002 015

105 014

023

022
021

018

019

Figure 1: Cross-section of Fluid End

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MAINTENANCE INSTRUCTIONS

Figure 2: Valve Seat Removal

Figure 3: Valve Seat Installation

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 MAINTENANCE INSTRUCTIONS

4.4 Packing

Packing is available in a v-ring style as shown in Fig. 4. The v-ring set consists of a
lantern ring, a poly-pack seal, a metal packing ring, o-rings, backup rings, a single stack
v-ring, and a double stack v-ring.

INSTALLATION PROCEDURESV-RING STYLE

1. Check packing rings, lantern rings, and gland nuts for nicks and dings. Rework (if
possible) or replace excessively worn parts.

2. Thoroughly clean and check all plungers and gland nut bores for excessive wear or
contaminant build up. Replace or rework any damaged or excessively worn parts.

3. Care must be taken installing the packing ring with new o-rings and backup rings into
the fluid end.

4. Care must be taken not to damage the outer packing lips during installation. This is
facilitated by using a puller plate, nut, all-thread and puller disc.

Each of the packing rings must be pulled into the box individually. The gland nut is
installed and made up tight to the fluid end. Install the plunger.

5. During priming of the pump, the plungers should be lubricated again. Start the
pump; continue lubrication at 2-3 minute intervals during the first 10-15 minutes of
operation to provide proper packing break-in. No further adjustments are required.

026 002 015

027
014
024
025
023

022
021

019
020
018

Figure 4: Stuffing Box Assembly

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 MAINTENANCE INSTRUCTIONS

4.5 Fluid End

Disable the power unit before doing any maintenance work. To remove the fluid end
from the cradle area of the power end, refer to Fig. 1 and the previous section 4.3 on
plunger removal.

Disconnect suction and discharge flanges and accessories such as the pressure gauges.
Unscrew the plunger from the crosshead and slide the plunger forward a short distance
into the fluid end. Connect hoist to fluid end and tighten until snug.

Remove the eight 12-point cap screws from the fluid end. Raise and lower fluid end to
clear the fluid end adapters from the power frame.

When installing fluid end be sure the power frame and fluid end faces are clean.

Lift the fluid end and match the fluid end adapters to the power frame bores. Push the
fluid end toward the power frame. Install the eight cap screws and torque to value in
torque table.

4.6 Wiper Box

Each wiper box assembly is attached to the cradle by four 3/8" cap screws. After
removing the plungers and the 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, and the use of a seating disc is necessary to avoid damage or distortion to
seal case.

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

4.7 Connecting Rod Bearings

Disable the power unit before doing any maintenance work. The connecting rod and rod
bearings are in the Parts List in the back of this manual

Remove the rear cover from the power frame.

Remove the two 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 and marked for correct re-assembly.

Be careful not to lose dowel pins 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 replacing rod cap, keep both dowel pins in place. Match the marks on the rod cap
and base. Refer to torque table for the torque on the rod cap screws. Move the bearing
housing from side-to-side to check that the bearings turn freely on the crankshaft.

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 MAINTENANCE INSTRUCTIONS

If new bearings have been installed, refer to the "Start-up" procedure before operating the
pump.

4.8 Crosshead, Connecting Rod and Wrist Pin

Disable the power unit before doing maintenance work.

Refer to power end Parts List for parts assembly of the crosshead, connecting rod, and
wrist pin. The crosshead slide should be inspected whenever a crosshead is removed and
replaced if wear exceed specified tolerances.

To inspect power end components, removing the wiper boxes, plungers, and connecting
rod bearings.

Rotate the crankshaft until crosshead and wrist pin are centered inside the inspection
window on the side of the power frame. Remove the outside snap ring from the
crosshead, and pull the wrist pin from the crosshead and connecting rod

Remove the connecting rod cap screws and cap.

Remove one connecting rod at a time.

Rotate the crankshaft to the end of stroke of the rod to be removed. Push the rod forward
until it clears the crankshaft throw. Lower the connecting rod to the bottom of the power
end. Again, rotate the crankshaft until the crankshaft throw is on top. Remove the
connecting rod out the back of the power end.

To remove the crosshead, rotate it until it is free of the guides on the crosshead slide. Be
careful with your hands as pinching can occur. Remove the crosshead through the
inspection cover.

NOTE: On some power ends the gearbox blocks the inspection cover on one side.
All crossheads can be removed, in order from the opposite side.

Use a hydraulic press to remove and replace the wrist pin bushing on the connecting rod.
When replacing the bushing, be certain that the groove is in line with the drill hole on the
connecting rod for proper lubrication.

Clean and inspect all bearings and bearing surfaces.

Replace components as necessary. Excessive scoring or grooving of crossheads or

crosshead slides is generally caused by contamination of the lubrication system. Change
oil at specified intervals and keep filters clean.

Reinstall the crosshead with one snap ring in place. Rotate the crosshead until it falls into
the matched grooves on the crosshead slide. Push as far toward the wiper box as
possible.

With the crankshaft throw in the top position, lift the connecting rod into a position as far
forward toward the crosshead as possible. Rotate the crankshaft to the end of the
backstroke. Install the connecting rod bearings and cap onto the crankshaft.

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 MAINTENANCE INSTRUCTIONS

Lift the wrist pin end of the connecting rod, slide the crosshead back and align the wrist
pin bores. Install the wrist pin and snap ring.

Install main bearing, retaining fasteners, pony rods and plungers. Run pump at slow
speed and check for complete oil lubrication.

Follow "Start-up" procedure on page. 8.

4.9 Crosshead Slide and Lubrication Assembly

The Parts List shows the crosshead slides and the lubrication assembly that connects the
power end lubrication system to the slide and crosshead.

Each bore has a top and bottom crosshead slide. The crosshead slides should be
inspected for wear and dimensional tolerance whenever the crosshead is removed.

To remove a crosshead slide, first disconnect the bulkhead fitting and free the slide from
the lubrication system. Then remove the two cap screws from the end of the slide.

Lift the crosshead slide and shims through the inspection window. Inspect guide for pits,
cracks or scoring and replace if necessary.

To replace crosshead slides and crosshead, correct shims must be used. Install crosshead
slides, crosshead and plunger. With a micrometer, measure the distance from the pony
rod to the wiper box seal bore on top and bottom. Subtract the smaller measurement
from the larger and divide by two for the correct shim pack. Torque the cap screws for
the crosshead slide to 50 ft. lbs. Care must be taken not to over torque.

Install the lower shim packs and lower crosshead slide. Tighten the slide cap screws.
Install the upper crosshead slide with no shims. Measure clearance with a feeler gauge.
Clearance should be .008" to .012" (0.2-0.3 mm). Adjust upper shim packs to achieve
this clearance.

Remove crosshead and slide. Add shim packs. Reassemble and check clearance. Install
cap screws and tighten. Reassemble crossheads, connecting rods, etc., per previous
instructions.

The lubrication assembly consists of lubrication tube and piping to allow oil to flow from
the power end lubrication system to the crosshead and crosshead slide. When starting
pump system, inspection should reveal that oil is flowing to all crossheads. Check hoses
at regular intervals (daily) and oil pressure to insure proper working order. A pressure
switch should be incorporated into the power end lubrication system to shutdown unit if
pressure falls below 20 psi (1.4 bar) at the far end of the lubrication tube (end opposite oil
supply).

4.10 Gearbox

Gearboxes are available in 4.6:1 ratio. Section 3.8 specifies recommended lubricants and
oil change intervals. Gearboxes are lubricated as part of the power end lubrication
system on standard pumps.

17
 MAINTENANCE INSTRUCTIONS
The gear box is designed to remove from the power end assembly in one piece. This is
accomplished by removing the eight 7/8 nuts from the power end flange. This gearbox
does not have an idler and reverses direction of rotation.

4.11 Crankshaft and Bearing Assembly

The crankshaft and bearing assembly are shown in the Parts List in the back of this
manual.

Inspect the crankshaft and bearings at regular intervals for wear and discoloration.
Observe oiling with covers off whenever starting the pump after overhaul. Oil should
flow freely over all four bearings. Calipers can be used for dimensional checks on worn
areas under connecting rod bearings.

If removal and possible rebuilding or replacement of the crankshaft is required or

removal of bearings is required, the pump will have to be removed from its skid. Disable
the power unit before doing maintenance work. Drain oil from the power frame.
Disconnect suction and discharge flanges. Disconnect the drive line from the gearbox.
Remove pump from skid and if possible do further maintenance in a repair shop with a
clean environment.

Remove the gearbox per the previous section. Disconnect the connecting rods,
crossheads, plungers and remove as previously described

Remove the lube bearing housing.

Turn the pump on its side with the crankshaft extension up. Attach a lifting eye to the
end of the crankshaft, lift up on the crankshaft. If necessary apply heat to the bearing
retainer to break it loose from the power end. Keep temperature under 250o F (120o C).
Slowly lift, pulling the cylindrical bearings through their races. It may be necessary to
rotate the crankshaft to allow the bearings to separate from the races.

Remove the bearing retainer, shaft bearing housing, spherical bearing, and cylindrical
bearings from the crankshaft. Low heat may be required for removal.

If required, remove cap screws, lock nut and retaining washers from cylindrical bearing
races still in power end. Remove the races by tapping with a bronze bar.

Follow above directions in reverse order for re-assembly. Use start-up procedures to
"break-in" power end after any major overhaul.

4.12 Lubrication System

The standard Omega pump is not equipped with a sump on the power end. Optional bolt-
on sumps and reservoirs can be purchased or are part of skidded pump units.

Refer to Table 1 for lubrication specifications. Approximately 40 gallons (150 liters) of

oil are needed for the W600S lubrication system.

Fig. 5 shows a typical power end lubrication diagram with engine drive. Pumps that are
shipped as part of a package will include parts lists for the lubrication components.
Components may differ for various applications and power supplies.

18
 MAINTENANCE INSTRUCTIONS

The major components of a lubrication system as numbered in Fig. 10 include a gear

pump P02, oil sump or reservoir P11, relief valve P16, oil cooler P25, filter P21, vacuum
gauge P05, pressure gauge P07 and shutdown switch (not shown).

Select a gear pump with a flow of 12 to 18 USGPM capacity at rated speed. This should
result in a pressure reading of a minimum of 50 psi at the pressure switch mounted on the
lubrication tube on the triplex power end. Pressure switch should be mounted on the end
opposite the gearbox end. Gear pump can be drive by a PTO drive of an engine
transmission, or can be driven by pulley drive off the front of an engine, or powered
separately by electric motor on electric pump units.

The oil reservoir should have a minimum capacity of 30 US gallons (110 liters).

Hoses, cooler and filters will add approximately 10 US gallons (38 liters) to the system.
Reservoir will connect to power end, gearbox, gear pump, filter and cooler. Suction hose
to the gear pump should be 2 inches (50 mm) in diameter and as direct as possible. A
suction strainer of 125 (.12 mm) mesh should be located at the oil reservoir.

A sump heater may be incorporated into the oil reservoir for operation where ambient
temperatures fall below 32o F (0o C).

The use of heavy gear oil requires careful selection of the oil filter. Filter should be rated
100 US gallons per minute (380 1/min.) at 300 psi (20 bar). An internal bypass of 30 psi
(2 bar) should be included. Filter element should be 25 micron.

It is necessary for both equipment protection and personnel safety to incorporate a relief
valve in the lubrication system. Relief valve should be set at 125 psi (8 bar) and should
connect directly from the gear pump discharge to the oil reservoir.

It is recommended that an oil cooler be part of the lubrication system. A check valve,
either integral with the cooler or external should be included to bypass full oil flow from
the cooler when the oil is cold (no need to cool cold oil) during warm-up.

Three gauges should be part of the system. The vacuum gauge connected to the gear
pump suction should read between zero and 10 inches (0-130 kPa) of Hg when oil
temperature exceeds 120o F (50o C). Pump cavitation and damage will occur if the
vacuum exceeds 20 inches of Hg (260 kPa). Clean suction strainer or repair gear pump if
high vacuum persists. A gauge on the gear pump discharge will assist with
troubleshooting. A normal reading would be 60 to 100 psi (4-7 bar). A combination
pressure switch and gauge on the lubrication tube will protect the power end from
damage if the lubrication system fails. It is recommended that shutdown be set at 20 psi
(1.4 bar). Normal reading will be 35 to 60 psi (2.4 bar - 4.1 bar).

Pressure hose or piping should be either 1-inch, one-wire hydraulic hose or 1-inch
schedule 40 pipe.

A temperature gauge is a good addition to the system. Maximum temperature is 175o F

(80o C) with a normal operating temperature of 130 to 160o F (54-71o C). A temperature
safety switch set at 180o F (82o C) is recommended.

19
 MAINTENANCE INSTRUCTIONS

Figure 5: Typical Power End Lubrication Diagram

20
 MAINTENANCE INSTRUCTIONS

ASSEMBLY AAB-051340-999

ITEM
NO. PART NUMBER QTY. PART DESCRIPTION

1 001-050340-999 1 CHELSEA PTO

2 002-050322-001 1 GEAR PUMP
3 469-011616-238 2 NIPPLE
4 469-020016-238 1 TEE
5 228-000057-999 1 VACUUM GAUGE
6 469-042012-238 2 REDUCER
7 469-041204-238 2 REDUCER
9 AAA-051492-999 1 HOSE
10 468-014048-238 2 HOSE
11 AAC-051473-220 1 OIL RESERVOIR
12 467-020404-238 2 PIPE SWIVEL
13 469-020020-238 2 TEE
14 469-061616-238 2 STREET ELBOW
15 228-000056-999 1 PRESSURE GAUGE
16 458-030001-999 1 RELIEF VALVE
17 470-021616-238 3 SWIVEL ELBOW
18 484-100072-238 1 HOSE
19 161-200112-350 1 REDUCER
20 469-042416-238 2 REDUCER
21 002-059283-003 1 FILTER
22 484-100180-238 2 HOSE
23 467-012020-238 1 ADAPTER
24 470-011616-238 1 SWIVEL NIPPLE
25 001-050294-999 1 OIL COOLER
26 469-042016-238 3 REDUCER
27 167-112300-250 1 STREET ELBOW
31 230-200080-551 1 PIPE NIPPLE
32 166-200300-250 1 PIPE ELBOW
33 002-059283-013 4 HOSE NIPPLE
34 002-059283-014 4 HOSE CLAMP
35 AAA-051464-009 1 HOSE, 2" x 9"
36 167-200300-250 2 STREET ELBOW
37 AAA-051464-011 1 HOSE, 2" x 11"
39 AAB-051467-231 1 GAUGE BRACKET (NOT SHOWN)
40 484-100048-238 1 HOSE
42 469-011620-238 1 PIPE NIPPLE
43 469-041208-238 1 REDUCER
44 469-011212-238 1 PIPE NIPPLE
45 469-020012-238 1 TEE
47 469-081612-238 1 REDUCER

21
 MAINTENANCE INSTRUCTIONS

4.14 Packing Lubrication

Packing requires lubrication with lubricant as specified in Table 1 on page 8.

Fig. 6 shows a proven lubrication schematic for automatic lubrication. The equipment
included in this system 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 that 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 (6.9-8.6 bar). 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 (2-3 bar) 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 1-050342 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
(6 mm) 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.

22
MAINTENANCE INSTRUCTIONS

Figure 6: Lubrication Schematic

23
MAINTENANCE INSTRUCTIONS

Drawing 1-050342

24
 MAINTENANCE INSTRUCTIONS

5.0 FASTENER TORQUES

Plunger 250 350 ft. lbs.

Fluid End 1 inch Bolts 500 ft. lbs.

Fluid End 1-3/8 inch Bolts 1300 ft lbs.

Bolt, Crosshead Slide 50 ft. lbs.

Bolt, Connecting Rod 135 ft. lbs.

25
 LOCATING TROUBLE
TROUBLE PROBABLE CAUSE
Pump vibrates or pounds. Gas in liquid.
Pump valve stuck open.
Pump not filling.
One or more cylinders not pumping.
Excessive pump speed.
Worn valve or seats.
Broken or missing springs.
Loose or worn bearings.
Worn crossheads.
Loose wrist pin or crank.
Loose connecting rod cap bolts.
Water in power end crankcase.
Consistent knock. Worn or loose main bearing,
crank pin bearing, wrist pin
bushing, piston and/or valve seat.
Excessive heat in Oil in crankcase.
power end.
Overloaded.
Pump crankshaft turning backwards.
Poor lubrication.
26
REMEDY
Submerge return, supply or make-
up lines in suction supply tank.
Stop. Remove debris beneath
valve.
Increase suction pressure.
Stop. Prime all cylinders.
Reduce.
Replace or reface.
Replace.
Tighten or replace.
Replace.
Replace or adjust. Check
tolerances.
Drain. Refill with clean oil
Replace or adjust. Check oil
level in crankcase. Level may be
too low or water may have
worked in through the wiper
boxes.
Check level, quality,
contamination, etc.
Normal operating temperature
from ambient to approximately
180o F maximum.
Check conditions of service.
Check arrow on pump or on
elevation drawing.
Check power end lubrication
system.
 LOCATING TROUBLE
TROUBLE PROBABLE CAUSE
Pump fails to deliver Speed incorrect. Belts slipping.
required capacity.
Air leaking into pump.
Fluid cylinder valves, seats or
plunger packing worn.
Not enough suction pressure above
vapor pressure.
Pump not filling.
One or more cylinders not pumping.
Stuck foot valve.
Fluid valve stuck open.
Clogged suction strainer.
Relief or bypass valves leaking.
Low volumetric efficiency.
Suction and/or discharge Piping too small and/or too long.
piping vibrates or pounds. Too many elbows.
Worn valve or seats.
27
REMEDY
Check with tachometer and
change drive ratio or tighten belts
if loose.
Check all joints. Hydrotest. Seal
with compounds.
Replace valves and seats.
Replace packing or plungers.
Increase static head or use a
booster pump.
Prime pump. Install foot valve at
bottom of suction pipe if suction
lift is used. Make-up in section
tank less than displacement of
pump. Capacity of booster pump
less than displacement of pump.
Vortex in supply tank.
Stop. Prime all cylinders.
Clean.
Stop. Remove debris beneath
valve.
Clean or remove.
Check and repair.
Liquid with low specific gravity
or high discharge pressure
compressing and expanding in
pump. Worn valves or seats. Air
in fluid.
Increase size and decrease length.
Use booster pump. Use suction
and/or discharge pulsation
dampeners. (See Sec. 4.5)
Replace.
 LOCATING TROUBLE

TROUBLE PROBABLE CAUSE REMEDY

Wear of fluid end parts Abrasive or corrosive action of
(excessive). the fluid.
Broken valve springs.
Bypassing to suction.
Incorrect material.
Check valves and seats frequently
at start-up to determine schedule
for replacement.
Eliminate sand, abrasives, or air
entering pump.
Replace.
Replace worn parts.
Check with pump manufacturer.

Wear of power end parts Poor lubrication. Check. Replace oil as

(excessive). 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
29
 013 031 035 038
014 039
040

034

037

005
007

036

010
011

024 010 008 019 028 030 035

026 009 029

010
025 224 020 016 001 011 003 004
012

033
041

032
042
043

125

021 016 022 015 202 023 010 006

203 16 011 012
 OMEGA PARTS LIST FOR
MODEL W600S POWER END

ITEM ITEM
NO. PART NUMBER QTY. PART DESCRIPTION/SIZE NO. PART NUMBER QTY. PART DESCRIPTION/SIZE

001 AAD-052500-232 1 POWER FRAME

002 AAA-051644-405 1 NAME PLATE, OMEGA
003 AAB-113766-000 1 AIR BREATHER
004 AAB-052512-231 1 TOP COVER
005 AAA-052529-204 1 GASKET, REAR COVER
006 AAB-052513-231 1 BOTTOM COVER
007 AAA-052514-282 1 REAR COVER
008 AAA-052515-282 2 INSPECTION COVER * ~ NOT SHOWN ON PARTS DRAWING
009 AAA-052530-204 2 GASKET, INSP COVER
010 100-038034-290 74 CAP SCREW
011 189-038081-286 74 WASHER NOTE: WHEN ORDERING PARTS, GIVE
012 AAA-052531-204 2 GASKET, COVER 1) PUMP SERIAL NUMBER
013 100-078114-290 4 CAPSCREW 2) PUMP MODEL NUMBER
014 AAB-052553-231 2 FOOT, POWER FRAME 3) PART NUMBER
015 AAC-052503-999 3 CONNECTING ROD ASSY 4) QUANTITY
016 AAB-052520-302 3 BUSHING, CONN ROD 5) PART DESCRIPTION
017 147-038034-220 6 DOWEL PIN, CONN ROD 6) ITEM NUMBER
018 AAA-052542-999 12 BOLT & WASHER, C ROD
019 AAC-052502-220 3 CROSSHEAD
020 AAB-052501-353 6 SLIDE, CROSSHEAD
021 AAB-052510-B27 3 WRIST PIN
022 AAB-052518-306 3 BEARING, CONN ROD, ROD
023 AAB-052519-306 3 BEARING, CONN ROD, CAP
024 AAA-052517-274 3 WASHER, CROSSHEAD
025 AAA-052507-274 3 BOLT, CROSSHEAD
026 188-014012-273 3 CAP SCREW, WASHER
027 442-058400-290 12 CAP SCREW, DRILLED
028 177-000350-220 3 RETAINING RING
029 170-100003-220 3 PIPE PLUG, WRIST PIN
030 AAC-052511-220 1 CRANKSHAFT
031 AAB-052528-282 1 BEARING HOUSING, MAIN
032 AAA-052506-231 6 RETAINER, MAIN BEARING
033 AAA-052505-231 6 RETAINER, MAIN BEARING
034 AAA-052537-204 2 GASKET, MAIN BRG HSG
035 121-800107-999 2 MAIN BEARING, OUTER
036 121-115113-999 1 MAIN BEARING, INNER
037 121-115114-999 1 MAIN BEARING, INNER
038 104-078300-286 16 STUD
039 133-078009-286 16 NUT
040 189-078134-286 16 WASHER
041 442-038078-290 12 CAP SCREW
042 100-038100-290 6 CAP SCREW
043 154-038068-286 6 LOCK WASHER

Revision Date: 10/04/2001 REVISION PCN 7852 A-052574 Rev. A

 OMEGA PARTS LIST FOR
MODEL W600S GEAR BOX

ITEM ITEM
NO. PART NUMBER QTY. PART DESCRIPTION/SIZE NO. PART NUMBER QTY. PART DESCRIPTION/SIZE

001 AAC-052550-231 1 GEAR BOX

002 147-034100-220 3 DOWEL PIN
003 133-012013-286 19 NUT
004 154-012087-286 19 LOCK WASHER
005 100-012134-290 19 CAP SCREW
006 AAC-052551-220 1 BULL GEAR
007 AAC-052552-220 1 PINION
008 AAB-052556-231 1 BEARING COVER, OFF/PIN * ~ NOT SHOWN ON PARTS DRAWING
009 170-200004-350 6 PIPE PLUG
010 145-278438-999 1 OIL SEAL
011 202-000013-999 2 BEARING CUP, PINION NOTE: WHEN ORDERING PARTS, GIVE
012 203-000030-999 2 BEARING CONE, PINION 1) PUMP SERIAL NUMBER
013 AAB-052554-231 1 BEARING RETAINER, PIN 2) PUMP MODEL NUMBER
014 AAA-052557-282 2 SHIM SET, PINION 3) PART NUMBER
015 AAA-052538-274 1 WEAR RING, PINION 4) QUANTITY
016 100-012112-290 16 CAP SCREW 5) PART DESCRIPTION
017 154-012087-286 20 LOCK WASHER 6) ITEM NUMBER
018 203-000031-999 2 BEARING CONE, MAIN
019 202-000027-999 2 BEARING CUP, MAIN
020 AAB-052533-231 1 BEARING RETAINER, MAIN
021 AAA-052558-282 1 SHIM SET, MAIN
022 AAA-052539-204 2 GASKET, LUBE COVER
023 100-038078-290 4 CAP SCREW
024 154-038068-286 4 LOCK WASHER
025 AAB-052555-220 1 SPRAY BAR
026 AAA-052562-231 1 LUBE OIL COVER
027 170-018003-220 3 PIPE PLUG

Revision Date: 10/04/2001 REVISION PCN 7852 A-052575 Rev. A

 008 037
036 033
006 028
038
034 029
007
035
007
016
042 017
009

010

008

011
012
004 042
013
005 040
041 001

039 031

032

030

026 002
015 026 002 015
027
027
014 014
024
024
025
025
023 023

022 022
021
021
019 019
020
020 018 018

3.50 PACKING DETAIL 4.50 PACKING DETAIL

 OMEGA PARTS LIST FOR
MODEL W 600S 3.5-4.5 FLUID END

ITEM ITEM
NO. PART NUMBER QTY. PART DESCRIPTION/SIZE NO. PART NUMBER QTY. PART DESCRIPTION/SIZE

001 AAD-052525-297 1 FLUID END 026 110-000249-200 3 O-RING, 3.50

002 AAB-052573-274 1 ADAPTER, FLUID END 110-000355-200 3 O-RING, 4.50
003 AAA-051644-405 1 NAME PLATE, OMEGA
004 AAA-052543-290 4 CAP SCREW, OUTER 027 459-000249-999 3 BACKUP RING, 3.50
005 ABA-052543-290 4 CAP SCREW, INNER 459-000355-999 3 BACKUP RING, 4.50
006 AAB-052536-274 3 VALVE COVER
007 ADA-051717-583 3 SEAL, VALVE COVER 028 110-014012-290 3 CAP SCREW
008 AAB-052534-274 6 RETAINER NUT 029 155-014034-220 3 LOCK WASHER
009 AAB-052535-274 3 SUCTION COVER
010 AEA-051717-583 3 SEAL, SUCTION COVER 030 AAC-052549-220 1 SUCTION MANIFOLD, VIC
011 AAC-052541-274 3 CAGE, VALVE 031 110-000244-200 3 O-RING
032 110-034112-290 12 CAP SCREW
012 145-312400-999 3 OIL SEAL, 3.50
145-412512-999 3 OIL SEAL, 4.50 033 AAB-052563-274 2 DISCHARGE FLANGE
034 104-100312-286 8 STUD
013 AAB-052517-999 3 PLUNGER, COL 3.50 035 133-100008-286 8 NUT
AAB-052509-999 3 PLUNGER, COL 4.50 036 110-000230-200 2 O-RING
037 AAB-052546-274 2 GAUGE CONNECTION
014 AAB-052570-274 3 GLAND NUT, 3.50 038 AAB-052547-274 2 RETAINER NUT, G CONN
AAB-052526-274 3 GLAND NUT, 4.50
VALVES
015 170-014003-220 8 PIPE PLUG 039 AAA-052564-220 6 VALVE SEAT W/ O-RING
040 AAA-052565-001 6 VALVE WITH INSERT
016 AAB-052573-231 3 WIPER BOX, 3.50 041 6 INSERT
AAB-052508-231 3 WIPER BOX, 4.50 042 AAA-052566-999 6 VALVE SPRING

017 AAA-052559-204 3 GASKET, WIPER BOX OPTIONAL TOOLS

* 001-059021-220 1 HEX WRENCH
018 001-050894-012 3 PRESSURE RING, SSF 3.50 * 002-050229-220 1 SLIDE HAMMER
001-050894-014 3 PRESSURE RING, SSF 4.50 * ABB-051293-274 1 SPANNER WRENCH
* AAB-052522-220 1 PLUNGER TOOL
019 001-051025-454 3 PRESSURE RING, SF 3.50 * AAA-050897-999 1 HYDRAULIC VLV PULLER
001-051025-456 3 PRESSURE RING, SF 4.50 * AAC-051852-274 1 VALVE PULLER HEAD

020 001-050895-012 3 HEADER RING, 3.50

001-050895-014 3 HEADER RING, 4.50

021 AAB-052568-274 3 PACKING RING, 3.50 * ~ NOT SHOWN ON PARTS DRAWING

AAB-052560-274 3 PACKING RING, 4.50

022 AAB-052569-310 3 LANTERN RING, 3.50 NOTE: WHEN ORDERING PARTS, GIVE
AAB-052527-310 3 LANTERN RING, 4.50 1) PUMP SERIAL NUMBER
2) PUMP MODEL NUMBER
023 AFB-051289-999 3 WIPER RING, 3.50 3) PART NUMBER
AKB-051289-999 3 WIPER RING, 4.50 4) QUANTITY
5) PART DESCRIPTION
024 110-000245-200 3 O-RING, 3.50 6) ITEM NUMBER
110-000249-200 3 O-RING, 4.50

025 459-000245-999 3 BACKUP RING, 3.50

459-000249-999 3 BACKUP RING, 4.50

Revision Date: 10/04/2001 REVISION PCN 7852 A-052576 Rev. A