Crankshaft Pre-Assembly Instructions for Well Stimulation Pumps {1202, 6002} Caterpillar

Well Pump

WS255 (S/N: SR51-UP)

WS255 SS (S/N: BM51-UP)

WS255 XD (S/N: SR61-UP)

WSP255 (S/N: FNK1-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

Illustration 1	g06257882
(1) Crankshaft (2) 434-9864 Bearing As (3) 434-9865 Bearing (4) 434-9866 Bearing As (5) 492-4407 Bolt (6) 434-9920 Washer (7) 492-4406 Bolt (8) 434-9919 Washer (9) 6V-8801 Nut

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, 3, 4, and 5 should be frozen prior to installation.

Note: Races 1 and 6 are installed last, after the crankshaft is installed.

Note: Leave races 1 and 6 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, 4, 5, and 6).

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 2	g06024590
   (1) Crankshaft (7) 492-4406 Bolt (8) 434-9919 Washer (9) 6V-8801 Nut

4. Using a suitable lifting device, install crankshaft (1) into suitable supporting device. The crankshaft weighs approximately 733 kg (1616 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 six 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.

6. Beginning with the "Drive End" of the crankshaft pointing skyward, place five washers (8) onto the bottom face of bearing area 3 on the crankshaft. Use five bolts (7) and five nuts (9) to hold the washers in place temporarily.

   Note: All retaining washers must be installed with the recessed side facing the bolt head or nut.

   Note: Do NOT install the bearing retainers on the top side until the bearing is heated and slid into place. The bottom retainers locate the hot bearing in place.

7. 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.

8. 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	g06257884
   (1) Crankshaft (3) 434-9865 Bearing

9. Using heat-resistant welding gloves, carefully pass bearing inner race 3 (3) over bearing area 1 and bearing area 2 and down onto bearing area 3 against washers (8).

   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 nuts.

10. Place five washers (8) on the bottom face of bearing area 2 on the crankshaft. Use five bolts (7) and five nuts (9) to hold the washers in place temporarily.

11. Install bearing inner race 2 (3) onto bearing area 2 against washers (8).

12. Apply Loctite 262 High Strength Liquid Threadlocker to five bolts (5).

13. Install five washers (6) on the bottom face of bearing area 1 with five bolts (5).

    Torque the screws ... 87 N·m (64 lb ft)

14. Install the 434-9864 Bearing (inner race) on bearing area 1 and allow the bearing inner race to cool for a few minutes.

15. Apply Loctite 262 High Strength Liquid Threadlocker to ten nuts (9).

16. After bearing inner race 2 (3) and bearing inner race 3 (3) are cool, install washers (8) on the top face of the inner race with nuts (9).

    Torque the nuts ... 50 N·m (37 lb ft)

17. After the bearings have cooled, screw two lifting eyes into the holes in the end of the crankshaft. The holes are taped to 1 1/4-7.

18. Using a suitable lifting device, remove crankshaft (1) from a suitable supporting device. The crankshaft weighs approximately 733 kg (1616 lb).

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

20. Remove the two lifting eyes from the end of the crankshaft, and install the two lifting eyes into the opposite end of the crankshaft.
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    Illustration 4	g06026252
    (1) Crankshaft (4) 434-9866 Bearing

21. Using a suitable lifting device, install crankshaft (1) into suitable supporting device. The crankshaft weighs approximately 733 kg (1616 lb).

22. Place five washers (8) on the bottom face of bearing area 4 on the crankshaft. Use five bolts (7) and five nuts (9) to hold the washers in place temporarily.

23. After heating bearing inner race 4 (4) , slide the inner race over bearing area 6 and bearing area 5 onto bearing area 4 against washers (8).

24. Place five washers (8) on the bottom face of bearing area 5 on the crankshaft. Use five bolts (7) and five nuts (9) to hold the washers in place temporarily.

25. Install the 434-9866 Bearing (inner race) onto bearing area 5 against washers (8).

26. Apply Loctite 262 High Strength Liquid Threadlocker to five bolts (5).

27. Install five washers (6) on the bottom face of bearing area 6 with five bolts (5).

    Torque the screws ... 87 N·m (64 lb ft)

28. Install the 434-9864 Bearing (inner race) on bearing area 6 and allow the bearing inner race to cool for a few minutes.

29. Apply Loctite 262 High Strength Liquid Threadlocker to ten nuts (5).

30. After bearing inner race 4 and bearing inner race 5 are cool, install washers (8) on the top face of the inner race with nuts (9).

    Torque the nuts ... 50 N·m (37 lb ft)

    Note: Keep bearings and crankshaft covered until ready to install in frame to prevent contamination of the bearings from blowing particles.

Power Frame 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 6 race side.

1. Using a paint marker or black ink marker, mark the main bearing bores as 1 through 6 from left to right.

   Note: Outer race 1 and 6 are not installed until the crankshaft is installed in place in the power frame. These outer races are "held" bearing races locating the crank.

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   Illustration 5	g06019571

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   Illustration 6	g06013002
   Power Frame

2. Cool down bearing outer race 2 and bearing outer race 3 with liquid nitrogen or a freezer prior to installation.

   Note: Bearing outer race 2 and 3 have a 0.762 mm (0.030 inch) larger outer diameter than bearing outer races 1, 4, 5, and 6.

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   Illustration 7	g06024621
   (7) 492-4406 Bolt (8) 434-9919 Washer (9) 6V-8801 Nut

3. Install three bolts (7) and three washers (8) into the power frame with washers on one side only before installation. Use five nuts (9) to hold the bolts and washers in place temporarily.

4. Install bearing outer race 2 against washers (8).

5. Remove temporary nuts (9).

6. Apply Loctite 262 High Strength Liquid Threadlocker to three nuts (9).

7. Install three washers (8) and three nuts (9) onto three bolts (7) in the power frame.

   Torque bearing retainer nuts ... 50 N·m (37 lb ft)

8. Repeat the procedure for bearing outer races 3, 4, and 5.

   Note: Bearing outer races 1 and 6 do not have retaining nuts. Bearing outer race 1 and 6 will not be installed until the crankshaft is in place.