National Oilwell: W600S Omega

 

 

National Oilwell

W600S OMEGA  OPERATION MAINTENANCE MANUAL 

August 6, 2002

 

 

 

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 prolon prolong g the period of satisfactory 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 assist assistance. ance. To improve our products we must be informed of the problems and solutions that occur in the field. We request that you send us us short reports reports of your your experiences. Include the pump model and serial numbers, operating conditions, conditions, problems, and the solut solution, ion, 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 fol following lowing information wh when en you place an order. 1. 2. 3. 4. 5.

3.0

Part number and description (see Parts List in Appendix). Quantity of each part required. Fluid end/power end model and serial number. Purchase order or requisition number. Designation of the shipping method you prefer. If overseas shipment is involved, designate the name of the export and crating company you prefer.

GENERAL

 National Oilwell pumps, when properly installed, given proper care and regular maintenance will operate satisfactorily for for a long period of time. time. The following paragraphs discuss the general  principles that must be be considered to insure trouble-free 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 pos possible, sible, so as to make suction piping short short and direct. Provide ample headroom for crane, hoist 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 this manual.

1

 

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 operations have been completed. Check the coupling faces and flanges flanges of the pump for for true horizontal and and vertical position position by means of a level. Correct the  positions by adjusting adjusting the supports as required. required.

3.7 

Drive Shaft  Both short-coupled and tube-type Splicer 1810 drive lines are used to couple the engine clutch or transmission 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 maximum life. Angles should not not exceed 5 degrees for normal operations. Do not neglect drive drive shaft lubrication. lubrication. Use a quality of EP grease meeting the NLG1 NLG1 grade 2 specification. Grease every one to three months dep depending ending 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 shaft clears the pump housing, housing, the gearbox is reversible.

Recommended lubricant lubricant under normal operation is 85W-140 gear o oil. il. If equipment is kept in long term storage or is inactive, keep gearbox 90-95% filled. The lubricant in a new gearbox should should be changed after after 500 hours of operation. Clean with flushing oil. Under normal operating conditions, conditions, change the the lubricant every every six months. months. Refer to gearbox manual for specific recommendations. 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 instructions as they appear appear throughout this manual. The  power end and gearbox are pressure lubricated and are dependent on a properly operating system with correct lubricants.

2 

 

INSTALLATION PROCEDURE

4.0

PIPING 

4.1 

General  Pipes must line up naturally. They must NOT be forced into place wit with h flange bolts, as

this may force the pump out of of alignment. Pipes should be supported supported independently of  pump thereby not producing 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 blowout all piping piping before connecting connecting to pump. Use pipe dope 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; therefo therefore, re, 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. 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 most often caused by the detrimental detrimental effects of pulsation pulsation in the suction piping system. Additional suction suction head may may be required if the liquid contains dissolved gases. A charge pump should be installed installed as close as possible to the su supply pply 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 th than an 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 pumps to a common manifold. manifold. If manifolding is is required, the ma manifold nifold 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.

3 

 

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 required should be either long radius radius or 45o  elbows. All "dead ends" should be avoided. avoided. The piping should be be pressure tested.

Adequate provisions should should be made for anchoring and supporting the piping spans. spans. The  pump must be able to be isolated for servicing; therefore, a fully opening block valve should be located located in the discharge discharge piping. Also, to protect protect the pump, pump, a check valve should be employed. employed. To facilitate starting starting and to eliminate eliminate air, a vent or 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 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. acting. Correct for strain effect, as required, to obtain tru truee 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 the safety it affords. The relief valve sho should uld 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 require considerable ove over-pressure r-pressure to compres compresss the spring, before becoming fully open, creating cr eating 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 without excessive over-pressure. over-pressure. Available spring 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 pressure depending on spri spring ng design. By choosing a larger larger valve this increase 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. pulsation. Leakage will quickly ruin ruin the relief valve seat and this condition should be corrected.

4 

 

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. 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 pressure drops in the relief valve valve line when sizing the PRV. PRV. Where  possible, pipe the relief relief valve exhaust so that any leakag leakagee 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 installed near the pump in tthe he 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. system. However, in some pump pump piping system systems, s, especially multiple 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 operational conditions, and the layou layoutt 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 including all of the interconnected 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. 5 

 

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, et etc., c., as the pump pump parts. Careful selection is necessary to avoid joint failure.

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 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 discharge line block valve. Start pump driver and check direction of crankshaft rotation against 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 usually performed at the factory. factory. However, additional break-in break-in occurs up to approximately 100 100 hours of service. For example particles particles off of v various arious internal parts are emitted into the oil. Eventually, this will will cause contamination contamination of the lubrication lubrication system and  potential pump failure if not not frequently checked during the break-i break-in n 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 power end lubrication lubrication pump. 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, bushings, main bearings, rod bearings, bearings, pine  bearings, and gears for proper oiling. oiling.

4.

Increase engine RPM to full RPM. Check the vacuum gage reading at the power end lubrication pump suction. suction. Reading should should be less than 10 in HG. Check lubrication lubrication  pump discharge gage reading. Pressure should be 60-80 psi. Check the entire lubrication system for leaks. Relief valve on discharge discharge side of lu lubrication brication 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 power end for leakage an unusual noise. noise. Lubrication pump vacuum gage reading should not fall below 10 in HG (35 kPa). kPa). If it does, filters may be clogged; change as necessary. Discharge pressure 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 and temperatures. temperatures. Oil temperature temperature should 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. pressure. Again observe oil pres pressures sures and temperatures.

7 

 

START-UP PROCEDURE 10.

Shut pump down and let cool before beginning normal operations. Change oil and filter elements within the the first 50 hours of operation. Clean strainers when changi changing ng oil. If power end is too hot to touch, check temperature. temperature. If oil temperature is abov abovee 180O  F (82O C), stop pump pump and allow allow cooling to ambient temperature. Repeat break-in run. run. If oil O O temperature continues to exceed 180   F (82   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

Type of

 Ambient Temp. Temp. F

Safe Operating Temp. F

0-95 (-18o C to 35o C)  Above 95 95 (35o C) Below 0 (-18o C)

Up to 180 (82o C) Up to 200 (93o C) Up to 130 (54o C)

Service General Hot Cold

Viscosity SUS @ Centi- Pour Point F 100o F Stokes

Timken ISO  AGMA Rating 1 bl. Grade Grade

1165

252.00 10 (-12o C)

65.00

220.00 5 EP

1710

370.00 10 (-12o C)

65.00

320.00 6 EP

5 (-15o C)

60.00

68.00

350

76

SSU=Centistokes *4.62

PACKING LUBRICATION Liquid Pumped

Ambient Temp. F

Water, Saltwater

 Above 0

(-18o C)

Rock Drill Oil 100

General Service

Below 0

(-18o C)

Rock Drill Oil 46

Petroleum Products

 Above 1 10 0o (38o C)

 Any

Below –20

(-29o C)

Table 1: Lubrication Specifications

8 

Lubricant

Straight Mineral Oil Brake Fluid

2 EP

 

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 inspection interval changes should bescheduled recorded in the pump pumto p prevent service logs. In addition, somereplacement. items may may beConsult replacedfactory at regularly intervals their costly emergency for specific recommendations. recommendations.  2.0

OIL CHANGE

 Numerous factors determine determine oil change intervals. Should Should the oil become contaminated 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.

3.0 

2.1 2.2 2.3

Water - from oil seal, wiper seal, breather cap or gasket leakage. Solids - from initial break-in as a result of first use as a new or rebuilt power end. Dust, Sand or Dirt - from air-borne sources through the shaft and wiper seals or breather

2.4

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

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 gland nuts snug (excessive leakage, unsuitable unsuitable materials). 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).

9 

 

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 WRIST PINS,INTERVAL. BUSHINGS, END BEARINGS, OIL, SHOULDBEARINGS, BE CHANGED AT THIS INTERVAL . PRIOR TO ADDING ADDINGETC.,) NEW OIL, OIL CRANKCASE COVER SHOULD BE REMOVED AND ALL EXPOSED INTERIOR SURFACES WIPED CLEAN. PRIOR TO CRANKCASE COVER REPLACEMENT, CHECK TORQUE OF ALL CONN CONNECTING ECTING ROD BOLTS. BOLTS. CLEAN OR REPLACE 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).

10 

 

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 wrist lube pin bushings; -- Power end and pressure 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 (see discharge valve is located just beneath valve covercan in the part of the fluid end Fig. 1). Replacement of the springthe or valve valve body be upper accomplished without with out removing the valve seats. seats. If it is necessary to remove the discharge discharge valve seat, remove with valve seat puller puller available from National O Oilwell ilwell (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 suction valve seat, it is necessary to firs firstt 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 the forward stroke. The next step is to disassemble disassemble the valve components from from the valve seat. Seat removal is accomplished accomplished by the use of a  puller available from the the factory. Refer to Fig. 3 when installing installing valve seats. Take care to avoid damage of tapered deck deck-seating surfaces. Valve seats should be be DRIVEN into the seat deck until until firmly seated. This is done by using a flat disc and driving with a piece of pipe and a hammer.

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

11 

 

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 the crosshead and remove the plunger plunger through the fluid end. Threaded holes on the cylinder head cover are for attaching a lifting bar to assist in removal.

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

105 011 004 105 005

105 105 105

031

105

032 030

105

105

002

015

014

023

022 021 018

019

  Figure 1: Cross-section of Fluid End 12 

 

MAINTENANCE INSTRUCTIONS

Figure 2: Valve Seat Removal

Figure 3: Valve Seat Installation

13 

 

MAINTENANCE INSTRUCTIONS

4.4

Packing 

Packing is available available in a v-ring style as shown 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 PROCEDURES V-RING STYLE

1. Check packin packing g rings, rings, lantern rings, and and gland gland nuts for nicks nicks and dings. Rework (if  possible) or replace excessively excessively worn parts. 2. Thoroughly clean and check all all plungers and gland nut bores for excessive wear or contaminant build up. up. Replace or rework any damaged or excessively excessively worn parts. 3. Care must b bee taken installing installing the packing ring with new o-rings and backup rings into the fluid end. 4. Care must be taken not to damage the the outer packing lip lipss 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 into the box individual individually. ly. The gland nut is installed and made up tight tight to the fluid end. Install the plunger. 5. During priming of the pump, the the plungers plungers should should be lubricated again. Start the  pump; continue lubrication lubrication at 2-3 minute intervals during the first 10-15 min minutes utes of operation to provide proper 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 14 

 

 

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 and tighten until snug. Remove the eight 12-point 12-point cap screws from the flui fluid d end. Raise and lower fluid end tto o 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 flu fluid id end adapters to to the power frame bores. bores. Push the fluid end toward the the power frame. Install the eight eight cap screws and torque torque to value in torque table. 4.6

Wiper Box

Each wiper box assembly is attached attached to the cradle cradle by four 3/8 3/8"" cap screws. After removing the plungers plungers and the wiper box cap screws, the wiper box will will slide out. It is necessary to disconnect the plunger 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 unit before doing any maintenance maintenance work. The connecting rod and rod  bearings are in the Parts List in 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 during disassembly. Use a rubber or wooden hammer hammer to tap a bearing away from cap or base (bearing housing). Clean the new bearings an and d housings before replacing. When replacing rod cap, keep both both dowel pins in place. Match the marks on the ro rod d cap and base. Refer to torque torque table for the torque on the rod cap screws. screws. Move the bearing bearing housing from side-to-side to check that the bearings turn freely on the crankshaft.

15 

 

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 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 the power frame. Remove the outside outside snap ring 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 stroke of the rod to be removed. Push the rod forward until it clears the crankshaft crankshaft throw. Lower the connecting rod to the bottom of the power power end. Again, rotate rotate the crankshaft until the the crankshaft throw is on top. top. Remove the connecting rod out the back of the power end. To remove the crosshead, rotate it until until it is free of the guides on tthe he crosshead slide. Be careful with your hands as pin pinching ching can occur. Remove the crosshead 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 components as necessary. necessary. Excessive scoring scoring or grooving o off crossheads or crosshead slides is generally generally caused by contamination o off the lubrication system. Change oil at specified intervals and keep filters clean. Reinstall the crosshead with one one snap ring in place. Rotate the crosshead until until it falls into the matched grooves grooves on the crosshead slide. Push as far tow toward ard the wiper box 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 crankshaft to the the end of the the  backstroke. Install the connecting rod rod bearings and cap onto the crank crankshaft. shaft.

16 

 

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 snap ring. Install main bearing, 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. crosshead. Each bore has a top and bott bottom om crosshead slide. The crosshead slides should 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. system. Then remove the two cap screws from from the end of the slide. Lift the crosshead slide and shims through through the inspection window. Inspect guide for pits, cracks or scoring and replace if necessary. To replace crosshead slides and crosshead, crosshead, correct shims must be used. Install crosshead slides, crosshead and plunger. plunger. With a micrometer, measure measure the distance from the p pony ony rod to the wiper box seal bore bore on top and bottom. Subtract the smaller measurement measurement from the larger and divide divide by two for the correct shim pack. Torque the cap screws screws for the crosshead slide to 50 ft. ft. lbs. Care must be taken not to over torque. torque. Install the lower lower shim packs and lower crosshead slide. Tighten the slide slide cap screws. Install the upper crosshead crosshead slide with no no shims. Measure clearance with a feeler feeler gauge. Clearance should be .008" to .012" .012" (0.2-0.3 mm). Adjust upper shim shim packs to achieve this clearance. Remove crosshead and slide. slide. Add sshim him packs. Reassemble and check check clearance. clearance. Install cap screws and tighten. Reassemble crossheads, crossheads, connecting 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 lubrication system to the crosshead and crosshead slide. slide. When starting  pump system, inspection should reveal that oil is flowing to all crossheads. Check hoses at regular intervals (daily) and oil pres pressure sure to insure proper working order. 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 the lubrication tube (end oppo opposite site oil supply). 4.10

Gearbox 

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

17 

 

MAINTENANCE INSTRUCTIONS The gear box is designed to remove from the power power end assembly in one piece. This is accomplished by removing the eight 7/8” nuts from the 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 whenever starting the the pump after overhaul. overhaul. Oil should flow freely over all four bearings. bearings. Calipers can be used for dimensional 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 pump will have to be removed from its ski skid. d. Disable the power unit unit before doing doing maintenance work. Drain oil from the power power frame. Disconnect suction suction and discharge flanges. Disconnect the drive lline ine from the gearbox 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 connecting rods rods,, crossheads, plungers and remove as previously described Remove the lube bearing housing. Turn the pump on its side with the crankshaft crankshaft extension up. Attach a lifting eye to the end of the crankshaft, crankshaft, lift up on the the crankshaft. If necessary apply heat to to the bearing retainer to break it loose from the the power end. Keep temperature under under 250o F (120o C). Slowly lift, pulling the cylindrical bearings 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. crankshaft. Low heat may be required for removal. 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 with a bronze bar. Follow above directions directions in reverse order for re-assembly. 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 equipped with a sump on the power end. Optional bolton sumps and reservoirs can be purchased or are part of skidded pump units. Refer to Table 1 for lubrication lubrication specifications. Approximately 40 gallons gallons (150 liters) of oil are needed for the W600S lubrication system. Fig. 5 shows a typical power end lubrication 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 capacity at rated speed. This should result in a pressure reading of a minimum of 50 psi at the pressure switch mounted on the lubricationthe on the end. triplex Gear triplex powerpump end. can Pressure switchbyshould shoul d be drive mounted end opposite thtube e gearbox be drive a PTO of on an the 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 power end, gearbox, gear pump, filter and cooler. Suction hose to the gear pump should should be 2 inches (50 mm) in d diameter iameter and as direct as p possible. ossible. 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 selection of the oil filter. Filter should be rated 100 US gallons per minute (380 1/min.) at 300 psi (20 bar). bar). An internal bypass of 30 p psi si (2 bar) should be included. Filter element should be 25 micron. micron. It is necessary for both equipment protection and personnel safety to incorporate a relief valve in the lubrication system. 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 that an oil cooler be part of of the lubrication system. 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 should be part of the system. The vacuum gauge 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 cavitation and damage will occur if the vacuum exceeds 20 inches of Hg (260 kPa). Clean suction strainer or or repair gear pump if high vacuum vacuum persists. persists. A gauge on the gear pump discharge will assi assist st with troubleshooting.. A normal reading would troubleshooting would be 60 to 100 psi (4-7 bar). A combin combination ation  pressure switch and gauge on the lubrication tube will protect the power end from damage if the lubrication system fails. It is recommended that shutdow shutdown n be set at 20 psi (1.4 bar). Normal reading will be 35 to 60 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 temperature is 175o F (80o C) with a normal operating temperature of 130 to 160o (80o 160o F (54-71o (54-71o C). A temperature o o safety switch set at 180  F (82  C) is recommended.

19 

 

MAINTENANCE INSTRUCTIONS

Figure 5: Typical Power End Lubrication Diagram

20 

 

MAINTENANCE INSTRUCTIONS

 ASSEMBLY  ASSEMB LY AAB-051340-999 AAB-051340-999 ITEM NO.

PART NUMBER

QTY.

PART DESCRIPTION

1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 31 32

001-050340-999 002-050322-001 469-011616-238 469-020016-238 228-000057-999 469-042012-238 469-041204-238 AAA-051492-999 468-014048-238 AAC-051473-220 467-020404-238 469-020020-238 469-061616-238 228-000056-999 458-030001-999 470-021616-238 484-100072-238 161-200112-350 469-042416-238 002-059283-003 484-100180-238 467-012020-238 470-011616-238 001-050294-999 469-042016-238 167-112300-250 230-200080-551 166-200300-250

1 1 2 1 1 2 2 1 2 1 2 2 2 1 1 3 1 1 2 1 2 1 1 1 3 1 1 1

CHELSEA PTO GEAR PUMP NIPPLE TEE VACUUM GAUGE REDUCER REDUCER HOSE HOSE OIL RESERVOIR  PIPE SWIVEL TEE STREET ELBOW PRESSURE GAUGE RELIEF VALVE SWIVEL ELBOW HOSE REDUCER REDUCER FILTER HOSE ADAPTER SWIVEL NIPPLE OIL COOLER REDUCER STREET ELBOW PIPE NIPPLE PIPE ELBOW

33 34 35 36 37 39 40 42 43 44 45 47

002-059283-013 002-059283-014 AAA-051464-009 167-200300-250 AAA-051464-011 AAB-051467-231 484-100048-238 469-011620-238 469-041208-238 469-011212-238 469-020012-238 469-081612-238

4 4 1 2 1 1 1 1 1 1 1 1

HOSE CLAMP NIPPLE HOSE HOSE, 2" x 9" STREET ELBOW HOSE, 2" x 11" GAUGE BRACKET (NOT SHOWN) HOSE PIPE NIPPLE REDUCER PIPE NIPPLE TEE 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 lubrication schematic schematic for automatic lub lubrication. rication. The equipment included in thisregulator, system includes an air supplycheck (usually an air compressor, governor and tank), a filter air hose, gauges, 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 to the "air over oil" reservoir reservoir with necessary hos hoses es and valves. Tank should have have a valve at  bottom for draining water. 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 (6.9-8.6 bar). A check valve is required between between the compressor and tank to prevent back flow flow of air when the compressor is in neutral. neutral. The filter regulator should be be set at 30 to 40 psi (2-3 bar) for prop proper er packing lubrication. lubrication. The 3way valve allows venting of the system as well as shut-off for maintenance. The "air over oil" oil" reservoir and filter-regulator 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. pumps. Check valves are installed over each stuffin stuffing g box to prevent flow of high-pressure pumpage 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 cr oss to the other two stuffing boxes.

22 

 

MAINTENANCE INSTRUCTIONS

Figure 6: 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

REMEDY

Pump vibrates or pounds.

Gas in liquid.

Submerge return, supply or makeup lines in suction supply tank.

Pump valve stuck open.

Stop. Remove debris beneath valve. Increase suction pressure. Stop. Prime all cylinders. Reduce. Replace or reface. Replace. Tighten or replace. Replace. Replace or adjust. adjust. Check tolerances. Drain. Refill with clean oil

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 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 temperature from ambient to approximately 180o F maximum. Check conditions of service. Check arrow on pump or on

Overloaded. Pump crankshaft turning backwards.

elevation drawing. Check power end lubrication system.

Poor lubrication.

26 

 

  LOCATING TROUBLE TROUBLE

PROBABLE CAUSE

REMEDY

Pump fails to deliver required capacity.

Speed incorrect. Belts slipping.

Check with tachometer and change drive ratio or tighten belts

Air leaking into pump. Fluid cylinder valves, seats or  plunger packing worn.  Not enough suction pressure 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.

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 pipe if suction lift is used. used. Make-up in section 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.

Suction and/or discharge

Piping too small and/or too long.

Increase size and decrease length.

 piping vibrates or pounds. pounds.

Too many elbows.

Use booster booster pump. Use suction suction and/or discharge pulsation dampeners. (See Sec. 4.5) Replace.

Worn valve or seats.

27 

 

  LOCATING TROUBLE TROUBLE

PROBABLE CAUSE

REMEDY

Wear of fluid end parts (excessive). 

Abrasive or corrosive action of the fluid. 

Check valves and seats frequently at start-up to determine schedule

Broken valve springs.  Bypassing to suction.  Incorrect material. 

for replacement.  Eliminate sand, abrasives, or air entering pump. Replace.  Replace worn parts.  Check with pump manufacturer. 

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 of service conditions against conditions on original order. If operating conditions greater, check with  pump manufacturer.  Stop. Replace packing and parts affected. Continued operation with excessive leaking rod  packing will ultimately allow entry of fluid into power end. 

Fluid entry into power end. 

28 

 

 

29 

 

013

035

031

038

014

039 040 034

037

005 007

036

010 011

010

024 026

008

019

009

035

030

028 029

010 025

224

020

016

001

011

003

004 012

033 041

032 042 043

125

021

016

022

015

202 203

023 16

010

006

011

012

 

OMEGA PARTS LIST FOR MODEL W600S POWER END

ITEM   NO.

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043

PAR PART T NU NUMBE MBER R

QTY. QTY. PART PART DE DESC SCRI RIPT PTIO ION/ N/SI SIZE ZE

AAD-052500-232 AAA-051644-405 AAB-113766-000 AAB-052512-231 AAA-052529-204 AAB-052513-231 AAA-052514-282 AAA-052515-282 AAA-052530-204 100-038034-290 189-038081-286 AAA-052531-204 100-078114-290 AAB-052553-231 AAC-052503-999 AAB-052520-302 147-038034-220 AAA-052542-999 AAC-052502-220 AAB-052501-353 AAB-052510-B27 AAB-052518-306 AAB-052519-306 AAA-052517-274 AAA-052507-274 188-014012-273 442-058400-290 177-000350-220 170-100003-220 AAC-052511-220 AAB-052528-282 AAA-052506-231 AAA-052505-231 AAA-052537-204 121-800107-999 121-115113-999 121-115114-999 104-078300-286 133-078009-286 189-078134-286 442-038078-290 100-038100-290 154-038068-286

1 1 1 1 1 1 1 2 2 74 74 2 4 2 3 3 6 12 3 6 3 3 3 3 3 3 12 3 3 1 1 6 6 2 2 1 1 16 16 16 12 6 6

Revision Date: 10/04/2001

POWER FRAME NAME PLATE, OMEGA AIR BREATHER TOP COVER GASKET, REAR COVER BOTTOM COVER REAR COVER INSPECTION CO C OVER GASKET, INSP COVER CAP SCREW WASHER GASKET, C CO OVER CAPSCREW FOOT, PO POWER F FR RAME CONNECTING ROD ASSY BUSHING, C CO ONN RO ROD DOW EL PIN, CONN ROD BOLT & WASHER, C ROD CROSSHEAD SLIDE, C CR ROSSHEAD WRIST PIN BEARING, CO CONN R RO OD, RO ROD BEARING, CO CONN R RO OD, CA CAP WASHER, CROSSHEAD BOLT, CROSSHEAD CAP SCREW, WASHER CAP S SC CREW , D DR RILLED RETAINING RING PIPE PLUG, WRIST PIN CRANKSHAFT BEARING HOUSING, MAIN RETAINER, MAIN BEARING RETAINER, MAIN BEARING GASKET, MAIN BRG HSG MAIN B BE EARING, OU OUTER MAIN B BE EARING, IIN NNER MAIN B BE EARING, IIN NNER STUD NUT WASHER CAP SCREW CAP SCREW LOCK WASHER

ITEM   NO.

PAR PART T NU NUMBE MBER R

QTY. QTY. PAR PART T DESC DESCRI RIPT PTIO ION/ N/SI SIZE ZE

* ~ NOT SHOWN O ON N PA PARTS RTS DRAWING

NOTE: NOT E: WHE WHEN N OR ORDER DERING ING PAR PARTS TS,, GI GIVE VE 1) PUMP SERIAL NUMBER 2) PUMP MODEL NUMBER 3) PART NUMBER 4) QUANTITY 5) PART DESCRIPTION 6) ITEM NUMBER

REVISION PCN 7852

A-052574 Rev. A

 

 

 

 

OMEGA PARTS LIST FOR MODEL W600S GEAR BOX

ITEM NO.

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027

PART NUMBER

QTY. PART DESCRIPTION/SIZE

AAC-052550-231 147-034100-220 133-012013-286 154-012087-286 100-012134-290 AAC-052551-220 AAC-052552-220 AAC-052552-220 AAB-052556-231 170-200004-350 145-278438-999 202-000013-999 203-000030-999 AAB-052554-231 AAA-052557-282 AAA-052538-274 100-012112-290 154-012087-286 203-000031-999 202-000027-999 AAB-052533-231 AAA-052558-282 AAA-052539-204 100-038078-290 154-038068-286 AAB-052555-220 AAA-052562-231 170-018003-220

1 3 19 19 19 1 1 1 6 1 2 2 1 2 1 16 20 2 2 1 1 2 4 4 1 1 3

Revision Date: 10/04/2001

GEAR BOX DOWEL PIN NUT LOCK WASHER CAP SCREW BULL GEAR PINIO PINION N BEARING COVER, OFF/PIN PIPE PLUG OIL SEAL BEARING CUP, PINION BEARING CONE, PINION BEARING RETAINER, PIN SHIM SET, PINION WEAR RING, PINION CAP SCREW LOCK WASHER BEARING CONE, MAIN BEARING CUP, MAIN BEARING RETAINER, MAIN SHIM SET, MAIN GASKET, LUBE COVER CAP SCREW LOCK WASHER SPRAY BAR LUBE OIL COVER PIPE PLUG

ITEM NO.

PART NUMBER

QTY. PART DESCRIPTION/SIZE

* ~ NOT SHOWN 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 PCN 7852

A-052575 Rev. A

 

 

ITEM NO.

OMEGA PARTS LIST FOR MODEL W 600S 3.5, 4.0, 4.5 FLUID END

PART NUMBER

QTY. PART DESCRIPTION/SIZE

001 AAD-052525-297 1 FLUID END 002 AAB-052573-274 1 ADAPTER, FLUID END 003 AAA-051644-405 1 NAME PLATE, OMEGA 004 AAA-052543-290 4 CAP SCREW, OUTER 005 ABA-052543-290 4 CAP SCREW, INNER 006 AAB-052536-274 3 VALVE COVER 007 ADA-051717-583 3 SEAL, VALVE COVER 008 AAB-052534-274 6 RETAINER NUT 009 AAB-052535-274 3 SUCTION COVER 010 AEA-051717-583 3 SEAL, SUCTION COVER 011 AAC-052541-274 3 CAGE, VALVE --------------------------------------------------------------------------------012 145-312400-999 3 OIL SEAL, 3.50 145-400499-999 3 OIL SEAL, 4.00 145-412512-999 3 OIL SEAL, 4.50 --------------------------------------------------------------------------------013 AAB-052571-999 3 PLUNGER, COL 3.50  ABB-052509-E21 3 PLUNGER, COL 4. 4.00 00  AAB-052509-999 3 PLUNGER, COL 4. 4.50 50 --------------------------------------------------------------------------------014 AAB-052570-274 3 GLAND NUT, 3.50  ABB-052526-274 3 GLAND NUT, 4.00  AAB-052526-274 3 GLAND NUT, 4.50 --------------------------------------------------------------------------------015 170-014003-220 8 PIPE PLUG --------------------------------------------------------------------------------016 AAB-052572-231 3 WIPER BOX, 3.50  ABB-052508-231 3 WIPER BOX, 4.00  AAB-052508-231 3 WIPER BOX, 4.50 --------------------------------------------------------------------------------017 AAA-052559-204 3 GASKET, WIPER BOX --------------------------------------------------------------------------------018 001-050894-012 3 PRESSURE RING, SSF 3.50 001-050894-005 3 PRESSURE RING, SSF 4.00 001-050894-014 3 PRESSURE RING, SSF 4.50 --------------------------------------------------------------------------------019 001-051025-454 3 PRESSURE RING, SF 3.50 001-051025-455 3 PRESSURE RING, SF 4.00 001-051025-456 3 PRESSURE RING, SF 4.50 --------------------------------------------------------------------------------020 001-050895-012 3 HEADER RING, 3.50 001-050895-005 3 HEADER RING, 4.00 001-050895-014 3 HEADER RING, 4.50 --------------------------------------------------------------------------------021 AAB-052568-274 3 PACKING RING, 3.50  ABB-052560-274 3 PACKING RING, 4.00  AAB-052560-274 3 PACKING RING, 4.50 --------------------------------------------------------------------------------022 AAB-052569-310 3 LANTERN RING, 3.50  ABB-052527-310 3 LANTERN RING, 4.00  AAB-052527-310 3 LANTERN RING, 4.50 --------------------------------------------------------------------------------023 AFB-051289-999 3 WIPER RING, 3.50  AHB-051289-999 3 WIPER RING, 4. 4.00 00  AKB-051289-999 3 WIPER RING, 4. 4.50 50 ---------------------------------------------------------------------------------

Revision Date: 02/05/2003

ITEM NO.

PART NUMBER

024

110-000249-200

QTY. PART DESCRIPTION/SIZE

3

O-RING, FLUID END TO PACKING RING --------------------------------------------------------------------------------025 459-000249-999 3 BACKUP RING, FLUID END TO PACKING RING --------------------------------------------------------------------------------026 110-000245-200 3 O-RING, PACKING RING TO GLAND NUT, 3.50 110-000351-200 3 O-RING, PACKING RING TO GLAND NUT, 4.00 110-000355-200 3 O-RING, PACKING RING TO GLAND NUT, 4.50 --------------------------------------------------------------------------------027 459-000245-999 3 BACKUP RING, PACKING RING TO GLAND NUT, 3.50 459-000351-999 3 BACKUP RING, PACKING RING TO GLAND NUT, 4.00 459-000355-999 3 BACKUP RING, PACKING RING TO GLAND NUT, 4.50 --------------------------------------------------------------------------------028 100-014012-290 3 CAP SCREW 029 155-014034-220 3 LOCK WASHER 030 AAC-052549-220 1 SUCTION MANIFOLD, VIC 031 110-000244-200 3 O-RING 032 100-034112-290 12 CAP SCREW 033 AAB-052563-274 2 DISCHARGE FLANGE 034 104-100312-286 8 STUD 035 133-100008-286 8 NUT 036 110-000230-200 2 O-RING 037 AAB-052546-274 2 GAUGE CONNECTION 038 AAB-052547-274 2 RETAINER NUT, G CONN --------------------------------------------------------------------------------039 080129901 6 VALVE SEAT W/ O-RING 040 070113329 6 VALVE VALVE WITH INSERT 041 072442031 6 INSERT 042 055413546 6 VALVE SPRING --------------------------------------------------------------------------------043 100-038034-290 12 CAP SCREW --------------------------------------------------------------------------------OPTIONAL TOOLS

* * * * * *

001-059021-220 002-050229-220 ABB-051293-274 AAB-052522-220 AAA-050897-999 AAC-051852-274

1 1 1 1 1 1

HEX WRENCH SLIDE HAMMER SPANNER WRENCH PLUNGER TOOL HYDRAULIC VLV PULLER VALVE PULLER HEAD

* ~ NOT SHOWN 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 PCN 8117

A-052576 Rev. C