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
i

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
ii

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.

1


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.
2


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.

3


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.
4


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.
5


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.

6

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 140
o
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 180
o

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.
7

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 180
o
F,
stop pump and allow cooling to ambient temperature. Repeat break-in run. If oil
temperature continues to exceed 180
o
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
180
O
F
1165 10
O
F 65 220 5 EP
Hot
Above
95
O
F

Up to
200
O
F
1710 10
O
F 65 320 6 EP
Cold
Below
0
O
F

Up to
130
O
F
350 5
O
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

8

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.

9


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)
10


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.
11


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.

12


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.
13


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.
14


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.
17


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.

18


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.

19


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 60
o
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 120
o
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 100
o
F to 150
o
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; 160
o
F (if ambient temperature is less than or equal to
80
o
F) and 170
o
F (if ambient temperature is greater than 80
o
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 130
o
F before performing either troubleshooting or
service work. Keep gauges in good working order.
22

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 80
o
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
23

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


Min./Max.
Pinion shaft drive connection 29 Tooth Spline

All other dimensions same as W1300 above

24


Min./Max.
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 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 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
180
o
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.

29

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

30

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 DISPLACEMENT
FACTORS
DIAMETER @ 100% V.E. 100 150 200 250 330
CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE CAPACITY DISCHARGE
(1) PRESSURE PRESSURE PRESSURE PRESSURE PRESSURE
U.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 @ CAPACITY
REV. 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 2164
7.00 3.998 400 6486 600 5466 800 4100 1000 3280 1319 2485
6.75 3.718 372 6975 558 5878 744 4408 930 3527 1227 2672
6.50 3.448 345 7521 517 6338 690 4754 862 3803 1138 2881
6.00 2.938 294 8827 441 7438 588 5579 735 4463 970 3381
5.75 2.698 270 9612 405 8100 540 6075 675 4860 890 3682
5.50 2.468 247 10508 370 8855 494 6641 617 5313 814 4025
5.00 2.040 204 12712 306 10713 408 8034 510 6428 673 4869
4.50 1.652 165 15698 248 13229 330 9921 413 7937 545 6013
4.00 1.306 131 19857 196 16733 261 12550 327 10040 431 7606
INPUT BHP 1780 2250 2250 2250 2250
POWER
@ 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
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

DISCHARGE FLANGE OPTIONAL PARTS
671 AAB-051396-274 1 2" 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


NOTE:WHEN ORDERING PARTS, GIVE
3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

Revision Date: January 20, 2003 REVISION PCN 8121 A-052291 Rev. A
MODEL W1300 W2250

ITEM

626 110-000425-200 6 O-RING
627 459-000425-999 3 BACK-UP RING
641 110-000427-200 6 O-RING
646 459-000427-999 3 BACK-UP RING
649 AAC-051356-236 3 CAGE
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
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 AAB-051363-236 3 SPRING RETAINER

733 001-051025-005 3 PACKING SET
7331 001-050894-005 2 PACKING RING
7332 001-050895-005 1 HEADER RING

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

*671 AAB-051639-999 1 3 1502 MALE FLANGE
673 110-000338-220 2 O-RING

CONNECTION
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
ASS'Y (DOES NOT
8909 AAB-051047-220 1 PULLER HEAD

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


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

Revision Date: January 20, 2003 REVISION PCN 8121 A-051695 Rev. E
MODEL W1300 W2250

ITEM

626 110-000427-200 6 O-RING
627 459-000427-999 3 BACK-UP RING
641 110-000432-200 6 O-RING
646 459-000432-999 3 BACK-UP RING
649 004-050916-236 3 CAGE
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

733 001-051025-006 3 PACKING SET
7331 001-050894-014 2 PACKING RING
7332 001-050895-014 1 HEADER RING

865 998-231013-075 6 VALVE ASSEMBLY
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

*671 AAB-051639-999 1 3 1502 MALE FLANGE
673 110-000338-220 2 O-RING

CONN.
735 AAB-051512-999 3 4-1/2 X 18L PLUNGER
CONN.

OPTIONAL TOOLS
637 001-059021-220 1 2" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAB-051047-220 1 PULLER HEAD

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


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

Revision Date: January 20, 2003 REVISION PCN 8121 A-051503 Rev. D
MODEL W1300 W2250

ITEM

626 110-000427-200 6 O-RING
627 459-000427-999 3 BACK-UP RING
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
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
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 002-050913-274 3 SPRING RETAINER

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

865 998-231013-075 6 VALVE ASSEMBLY
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

*671 AAB-051639-999 1 3 1502 MALE FLANGE
673 110-000338-220 2 O-RING

CONNECTION
735 AAB-051513-999 3 5 x 18 LONG PLUNGER
CONNECTION

OPTIONAL TOOLS
637 001-059021-220 1 2" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAB-051047-220 1 PULLER HEAD

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


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

MODEL W1300 W2250

ITEM

600 AAD-051331-487 1 FLUID END, AUTOFR
626 110-000432-200 6 O-RING
641 110-000438-200 6 O-RING
649 AAC-051271-236 3 CAGE
651 110-000258-200 3 O-RING
652 100-078112-290 12 CAP SCREW
674 104-100312-286 12 STUD
675 133-100008-286 12 NUT
697 AAC-051272-274 3 GLAND NUT
703 998-BRS512-012 3 BRASS SET
711 110-000263-200 3 O-RING
713 APB-051289-999 3 WIPER SEAL
735 AAB-051285-999 3 5-1/2 X 16 L PLUNGER
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 002-050923-274 3 SPRING RETAINER

733 001-051025-011 3 PACKING SET
7331 001-050894-008 2 PACKING RING
7332 001-050895-008 1 HEADER RING

866 080121148 1 SEAT w/O-RING
867 110-000248-200 1 O-RING
868 070113402 1 BODY w/INSERT
870 072442254 1 INSERT
871 AAB-051162-999 1 SPRING

ITEM

671 004-050482-274 1 2" 1502 FEMALE FLANGE
*671 AAB-051641-999 1 3 1502 MALE FLANGE
672 AAB-051397-274 1 BLIND w/BLEED-OFF
672 004-050471-274 1 BLIND FLANGE
673 110-000344-200 2 O-RING

735 AAB-051514-999 3 5-1/2 X 18 L PLUNGER
633 AAA-051000-274 1 RETAINER NUT GAUGE
CONNECTION
CONNECTION

OPTIONAL TOOLS
637 001-059089-220 1 3" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAC-051048-220 1 PULLER HEAD

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 001-059014-274 1 PULL ROD
8908 133-200412-286 1 HEX NUT


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

Revision Date: January 20, 2003 REVISION PCN 8121 A-051698 Rev. D
MODEL W1300 W2250

ITEM

600 AAD-051083-487 1 FLUID END, AUTOFR
626 110-000432-200 6 O-RING
641 110-000438-200 6 O-RING
649 004-050914-236 3 CAGE
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-050924-274 3 GLAND NUT
703 998-BRS534-012 3 BRASS SET
711 110-000265-200 3 O-RING
713 AQB-051289-999 3 WIPER SEAL
735 002-050323-999 3 5-3/4 X 16 PLUNGER
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 002-050923-274 3 SPRING RETAINER

733 001-051025-019 3 PACKING SET
7331 001-050894-006 2 PACKING RING
7332 001-050895-006 1 HEADER RING

866 080121148 1 SEAT w/O-RING
867 110-000248-200 1 O-RING
868 070113402 1 BODY w/INSERT
870 072442254 1 INSERT
871 AAB-051162-999 1 SPRING

ITEM

671 004-050482-274 1 2" 1502 FEMALE FLANGE
*671 AAB-051641-999 1 3 1502 MALE FLANGE
672 004-050471-274 1 BLIND FLANGE
673 110-000344-200 2 O-RING

735 AAB-051515-999 3 5-3/4 X 18 L PLUNGER
CONNECTION
CONNECTION

OPTIONAL TOOLS
637 001-059089-220 1 3" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAB-051048-220 1 PULLER HEAD

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 001-059014-274 1 PULL ROD
8908 133-200412-286 1 HEX NUT


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER

MODEL W1300 W2250 MWA
6.00 INCH FLUID END ASSEMBLY

ITEM

600 AAD-052268-487 1 FLUID END MWA
625 AAB-050939-274 3 DISCHARGE COVER
626 110-000432-200 6 O-RING
640 AAB-051290-274 3 SUCTION COVER
641 110-000438-200 6 O-RING
649 004-050914-236 3 CAGE
650 AAC-050547-220 1 SUCTION MANIFOLD, VIC
WITH DRAINS
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-052174-274 3 GLAND NUT
703 998-BRS600-012 3 BRASS SET
713 ARB-051289-999 3 WIPER SEAL
735 AAB-051516-999 3 PLUNGER
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 002-050923-274 3 SPRING RETAINER

STYLE 1067 PACKING SET
733 001-051025-016 3 PACKING SET
7331 001-050894-007 6 PRESSURE RING
7332 001-050895-007 3 HEADER RING

MISSION VALVE ASSEMBLY
866 080121148 1 SEAT w/O-RING
867 110-000248-200 1 O-RING
868 070113402 1 BODY w/INSERT
870 072442254 1 INSERT
871 AAB-051162-999 1 SPRING
ITEM

671 004-050482-274 1 2" 1502 FEMALE FLANGE
*671 AAB-051641-999 1 3 1502 MALE FLANGE
672 004-050471-274 1 BLIND FLANGE
673 110-000344-200 2 O-RING

CONNECTION
CONNECTION

OPTIONAL TOOLS
637 001-059089-220 1 3" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAB-051048-220 1 PULLER HEAD

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 001-059014-274 1 PULL ROD
8908 133-200412-286 1 HEX NUT


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER
Revision Date: 12/10/02 REVISION PCN 8094-1 A-052280 Rev. A
MODEL W1300 W2250

ITEM

600 AAD-050898-487 1 FLUID END
626 110-000362-200 6 O-RING
640 AAA-050108-274 3 CYLINDER HEAD
641 110-000442-200 6 O-RING
649 004-050982-236 3 CAGE
651 110-000258-200 3 O-RING
652 100-078112-290 12 CAP SCREW
674 104-100312-286 12 STUD
675 133-100008-286 12 NUT
697 AAC-051277-274 3 GLAND NUT
703 998-BRS612-012 3 BRASS SET
711 110-000267-200 3 O-RING
713 ATB-051289-999 3 WIPER SEAL
735 002-050209-999 3 6-3/4 X 16 PLUNGER
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 AAA-051055-274 3 SPRING RETAINER

733 001-051025-018 3 PACKING SET
7331 001-050894-015 2 PACKING RING
7332 001-050895-015 1 HEADER RING

866 001-050638-220 1 SEAT w/O-RING
867 110-000256-200 1 O-RING
868 AAA-051968-001 1 BODY w/INSERT
870 AAA-051968-002 1 INSERT
871 AAB-051164-999 1 SPRING

ITEM

671 004-050482-274 1 2" 1502 FEMALE FLANGE
*671 AAB-051641-999 1 3 1502 MALE FLANGE
672 004-050471-274 1 BLIND FLANGE
673 110-000344-200 2 O-RING

735 AAB-051518-999 3 6-3/4 X 18 LONG
PLUNGER
CONNECTION
CONNECTION

OPTIONAL TOOLS
637 001-059089-220 1 3" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAC-051855-274 1 PULLER HEAD

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 001-059014-274 1 PULL ROD
8908 133-200412-286 1 HEX NUT


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER
MODEL W1300 W2250

ITEM

600 AAC-051780-487 1 FLUID END
626 110-000362-200 6 O-RING
641 110-000443-200 6 O-RING
649 AAC-051357-236 3 CAGE
650 008-050886-220 1 SUCTION MANIFOLD
651 110-000258-200 3 O-RING
652 100-078112-290 12 CAP SCREW
674 104-100312-286 12 STUD
675 133-100008-286 12 NUT
697 AAC-051815-274 3 GLAND NUT
703 998-BRS634-012 3 BRASS SET
711 110-000268-200 3 O-RING
713 AUB-051289-999 3 WIPER SEAL
735 AAB-051520-999 3 6-3/4 X 16 PLUNGER
746 AAB-050477-241 3 PUSH ROD CLAMP
w/CAP SCREWS
747 105-012112-290 6 CAP SCREWS
860 AAA-051055-274 3 SPRING RETAINER

733 001-051025-019 3 PACKING SET
7331 001-050894-011 2 PACKING RING
7332 001-050895-011 1 HEADER RING

866 080123029 1 SEAT w/O-RING
867 110-000256-200 1 O-RING
868 070113451 1 BODY w/INSERT
870 072442353 1 INSERT
871 AAB-051164-999 1 SPRING

ITEM

671 004-050482-274 1 2" 1502 FEMALE FLANGE
*671 AAB-051641-999 1 3 1502 MALE FLANGE
671 AAB-051648-274 1 3 602 FEMALE FLANGE
672 004-050471-274 1 BLIND FLANGE
673 110-000344-200 2 O-RING

735 AAB-051519-999 3 6-3/4 X 18 L PLUNGER
CONNECTION
CONNECTION

OPTIONAL TOOLS
637 001-059089-220 1 3" HEX WRENCH
648 002-050229-220 1 SLIDE HAMMER
COVER PULLER
ASS'Y (DOES NOT
8909 AAC-051855-274 1 PULLER HEAD

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 001-059014-274 1 PULL ROD
8908 133-200412-286 1 HEX NUT


3) PART NUMBER
4) QUANTITY
5) PART DESCRIPTION
6) ITEM NUMBER


Bobma Jedco - Omega F1000 W2250

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