Crankshaft Pre-Assembly Instructions for Well Stimulation Pumps {1202} Caterpillar

Well Stimulation Pump

WS223 (S/N: SR31-UP)

WS223 SS (S/N: BM31-UP)

WS223 XD (S/N: SR41-UP)

Well Stimulation Pump Power End

WSP223 (S/N: FNJ1-UP)

Introduction

This Special Instruction is intended to give information on pre-assembling the crankshaft for certain well stimulation pumps.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Also ensure that you are following all safety precautions while you are performing the procedures outlined in this document.

Safety Section

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Always wear protective gloves when handling parts that have been heated.

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Serious injury can result from failure to use personal protective equipment. Wear the appropriate personal protective equipment that is required for the tasks that are being performed.

Required Parts

Installation Procedure

Crankshaft Bearing Installation

Note: All bearings and races are shipped as a mated pair. If you damage a bearing race and the bearing race needs replaced, that corresponding bearing will need to be replaced as well.

Note: All the races are interference fit, races 2 and 3 should be frozen prior to installation.

Note: Races 1 and 4 are installed last, after the crankshaft is installed.

Note: Leave races 1 and 4 out about a 6.35 mm (0.25 inch) and use the retaining ring to pull the race flush.

Note: Take care not to mix up the inner races and outer races

1. Remove any excessive preservative coating or oil/grease from the inner and outer races

2. Using a paint marker or black Ink Marker, carefully mark the inner and outer races of each bearing with their proper location in the frame (i.e. 1, 2, 3, and 4).

3. Separate the marked bearings into inner races and outer races.

   The inner races will be installed on the crankshaft and be allowed to cool while the outer races are being installed in the power frame.

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   Illustration 1	g06019548
   (1) 434-9858 Crankshaft (2) 434-9867 Snap Ring

4. Using a suitable lifting device, install crankshaft (1) into suitable supporting device. The crankshaft weighs approximately 583 kg (1285 lb).

   Note: "Drive End" is marked on the end of the crankshaft next to number 1 throw.The number one bearing will be on this end of the crankshaft, and the number four bearing on the opposite end.

5. Locate the "Drive End" of the crankshaft and mark the first bearing area as 1, the next bearing area as 2, and so on.
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   Illustration 2	g06019556
   (2) 434-9867 Snap Ring

6. Beginning with the "Drive End" of the crankshaft pointing skyward, place snap ring (2) in the bottom groove of bearing area 2 on the crankshaft.

7. Using a small, cool torch, braze snap ring (2) around the perimeter in four places to prevent the snap ring from coming loose during pump operation. Ensure that the snap ring is sitting completely inside the ring groove.

   Note: Do NOT install top snap ring until the 434-9865 Bearing As is in place.

8. Place the bearing inner races in a dry oven (or oil bath) with the numbers located so that you can easily identify each bearing race.

9. Heat the bearing inner races to 135° C to 149° C (275° F to 300° F) for easier installation onto the crankshaft.
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   Illustration 3	g06019559
   (2) 434-9867 Snap Ring (3) 434-9865 Bearing As (Bearing 2)

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   Illustration 4	g06019560

10. Using heat-resistant welding gloves, carefully pass bearing 2 (3) over bearing area 1 and down onto bearing area 2 against snap ring (2).

    Note: The bearing inner races are heavy, so a small step-up or low step ladder is useful. A dead blow hammer is also useful in case the bearing inner race hangs up on the crankshaft prior to finding its final position on the snap ring.

11. Install snap ring (2) on top of bearing 2 (3) and braze in place.

    Note: Use a flat head screw driver to hold the snap ring in place while braze welding. Ensure that the snap ring is fully sitting in the groove and is flush.

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    Illustration 5	g06019562
    (2) 434-9867 Snap Ring

12. Place snap ring (2) in the bottom groove of bearing area 1 on the crankshaft.

13. Braze snap ring (2) around the perimeter in four places. Ensure that the snap ring is sitting completely inside the ring groove.
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    Illustration 6	g06019563
    (2) 434-9867 Snap Ring (4) 434-9864 Bearing As (Bearing 1)

14. Install bearing 1 (4) onto bearing area 1 against snap ring (2). Ensure that the bearing is sitting flush on top of the snap ring.

    Note: Bearing 1 is retained by a snap ring on the bottom and the spacer ring on the top. The spacer ring is installed after the crankshaft is installed in the power frame.

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    Illustration 7	g06019564

15. Screw two lifting eyes into the holes in the end of the crankshaft. The holes are tapped to 1 1/4-7.

16. Using a suitable lifting device, remove crankshaft (1) from a suitable supporting device. The crankshaft weighs approximately 583 kg (1285 lb).

17. Lay the crankshaft on a 1/2 inch or 3/4 inch piece of plywood to prevent damage to the bearings.

18. Remove the two lifting eyes from the end of the crankshaft, and install the two lifting eyes into the opposite end of the crankshaft.

19. Using a suitable lifting device, install crankshaft (1) into suitable supporting device. The crankshaft weighs approximately 583 kg (1285 lb).
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    Illustration 8	g06019568
    (2) 434-9867 Snap Ring (5) 434-9866 Bearing As (Bearing 3)

20. Carefully pass bearing 3 (5) over bearing area 4 and down onto bearing area 3 against snap ring (2).
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    Illustration 9	g06019570
    (2) 434-9867 Snap Ring (5) 434-9866 Bearing As (Bearing 3)

21. Install snap ring (2) on top of bearing 3 (5) and braze in place.

    Note: Use a flat head screw driver to hold the snap ring in place while braze welding. Ensure that the snap ring is fully sitting in the groove and is flush.

22. Place snap ring (2) in the bottom groove of bearing area 4 on the crankshaft.

23. Braze snap ring (2) around the perimeter in four places. Ensure that the snap ring is sitting completely inside the ring groove.

24. Install the 434-9864 Bearing As (Bearing 4) onto bearing area 4 against snap ring (2). Ensure that the bearing is sitting flush on top of the snap ring.

    Note: Bearing 4 is retained by a snap ring on the top and the bottom.

25. Install snap ring (2) on top of bearing 4 and braze in place.

    Note: Use a flat head screw driver to hold the snap ring in place while braze welding. Ensure that the snap ring is fully sitting in the groove and is flush.

26. Allow the crankshaft to cool to room temperature.

    Note: Keep bearings and crankshaft covered until ready to install in frame to prevent contamination.

Power Frame Outer Bearing Race Installation

Note: The drive side, or left side from the back of the power frame, is the number 1 bearing race side, and the off-put side is the number 4 race side.

1. Using a paint marker or black ink marker, mark the main bearing bores as 1 through 4 from left to right.

   Note: Outer races 1 and 4 are not installed until the crankshaft is installed in place in the power frame.

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   Illustration 10	g06019571

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   Illustration 11	g06019575

2. Cool down the 434-9865 Bearing As (Bearing Outer Race 2) with liquid nitrogen or a freezer prior to installation.

   Note: Bearing outer race 2 has a 0.762 mm (0.030 inch) larger outer diameter than bearing outer race 3.

3. After installing outer race 2, immediately install the 434-9908 Snap Ring.

4. Braze the 434-9908 Snap Ring around the perimeter in four places.

5. Cool down the 434-9866 Bearing As (Bearing Outer Race 3) with liquid nitrogen or a freezer prior to installation.

6. After installing outer race 3, immediately install the 434-9908 Snap Ring and braze in place.

Reference Section

Reference: Disassembly and Assembly, UENR6796 for additional information.