Specifications and Salvage for Well Stimulation Fluid End {0374, 0599, 0679, 5070, 7000} Caterpillar

Specifications and Salvage for Well Stimulation Fluid End {0374, 0599, 0679, 5070, 7000}

Usage:

Industrial Engine: 4006D-E23TA (S/N: DE61-UP); 4008D-E30TA (S/N: DE81-UP)
Well Pump: WS223 (S/N: SR31-UP); WS223 XD (S/N: SR41-UP); WS255 (S/N: SR51-UP); WS255 XD (S/N: SR61-UP); WSF223 (S/N: FN41-UP; FNL1-UP); WSF223 SS (S/N: BM41-UP; BM81-UP; FNS1-UP); WSF223 XD (S/N: FN31-UP; FNM1-UP); WSF243 SS (S/N: RX21-UP; RX31-UP; RX41-UP; RX51-UP); WSF243 XD (S/N: FN91-UP; FNC1-UP; FND1-UP; FNE1-UP); WSF253 SS (S/N: RWC1-UP; RWD1-UP); WSF253 XD (S/N: FN81-UP; FNT1-UP); WSF255 (S/N: FN51-UP; DF61-UP; FN61-UP; FN71-UP; DF81-UP; DF91-UP); WSF255 SS (S/N: BM61-UP; BM71-UP; BM91-UP); WSF255 XD (S/N: FN21-UP; P231-UP; FNP1-UP); WSF273 XD (S/N: DG41-UP; DG51-UP; DG61-UP); WSF275 SS (S/N: RX61-UP; RX71-UP; RX81-UP; RX91-UP); WSF275 XD (S/N: FNB1-UP; FNF1-UP; FNG1-UP; FNH1-UP); WSF305 XD (S/N: EA41-UP; EA51-UP; EA61-UP; EA71-UP)

Introduction

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Table 1
Revision	Summary of Changes in SEBF9374
02	Added serial number prefixes, Modified Illustrations 30 and 31. Updated Tables 32 and 33. Revised headers of each table and added the "Crack Detection Methods" section.
01	Added serial number prefixes for New Product Introductions
00	Initial Issue

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This guideline enables dealers and dealer customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current information known to Caterpillar Inc. Since the company makes ongoing product changes and product improvements, this guideline must be used with the latest technical information. Using the latest technical information available from Caterpillar ensures that such changes and improvements are incorporated where applicable.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS Web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. CaterpillarEnsure that the procedure is safe for you and for other people to use by following the recommended procedures and service tools. Ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

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Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Safety

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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

Summary

This guideline gives specifications and repair procedures for new and used fluid ends. A fluid end repaired based on the specifications in this guideline can be expected to give normal performance. Life will vary depending on application, load, lubrication, and environment.

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part is expected to reach the next Planned Component Rebuild (PCR) if the part meets the specifications within this guideline and the part is intended for a similar application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

References

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Table 2
Media Number	Publication Type & Title
PERJ1017	Special Publication "Dealer Service Tools Catalog"

Service Advisories, Service Letters, and Technical Service Bulletins

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NOTICE

The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

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Table 3
Required Tooling and Equipment
Part Number	Part Description
— ⁽¹⁾	Personal Protective Equipment (PPE)
—	Loctite 242
—	Bully Dog Stud Driver (16B-8-12)⁽²⁾
—	Thread Profile Gauge⁽³⁾
434-9945	Tool Assembly
434-9949	Slide Hammer Assembly
434-9950	Tool Packing Nut
434-9951	Tool Assembly
316-1495	Hydraulic Cylinder
1U-9889	Crossblock
4C-9634	Puller Stud (1-1/4X12-29-IN)
1P-1837	Bearing Puller Adapter
385-8467	Unit Drive
384-8916	Hydraulic Pump Group
1U-6857	Abrasive Material 180 Grit
1U-8281	Abrasive Sheet 400 Grit
1U-5691	13/16 Drill
1U-5694	29/32 Drill
8S-2257	Magnifying Glass
4C-9442	Light
262-8390	Microscope (40-Power) Pocket
288-4209	Paper Towel
—	Developer
—	Penetrating Oil
—	Solvent Cleaner
459-0184	Lamp Group Ultraviolet

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⁽¹⁾	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
⁽²⁾	Refer to Titan Tool Company in Supplier section
⁽³⁾	Refer to Gagemaker in Supplier section

Suppliers

Titan Tool Company
7410 West Ridge Rd.
Fairview, PA 16415, USA
(814) 474-1583
Email: titan@titantoolco.com

Gagemaker
712 East Southmore Avenue
Pasadena, TX 77502, USA
(713) 472-7360
Email: sales@gagemaker.com

Magnaflux
155 Harlem Avenue
Glenview, IL 60025, USA
(847) 657-5300
Web address: https://www.magnaflux.com

Cleaning

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NOTICE

Failure to remove all dirt, debris, and/or metal shavings from openings, ports and passages will result in damage to the fluid end and the related components.

All well stimulation pump fluid ends should be cleaned with an Abrasive blasting based on MIL-STD-1504.

Notes

Welding Specification

Semi-Automatic (GMAW) Gas Metal Arc Welding

400 - 450 amp power source is recommended

Gas Tungsten Arc Welding (GTAW) or (TIG)

At least a 350 amp DC TIG power supply recommended for GTAW
Shielding gas 100% Argon

Caterpillar recommends using only Inconel 625 wire, similar to the one in Table 4.

Stainless Steel

Correctly identify stainless steel from carbon steel before the salvage process starts. A 5 percent solution of copper sulfates applied to the top of the fluid end should confirm the differences between non-stainless steels and stainless steels. The clear solution will turn a metallic copper color on non-stainless steels, but should remain free of copper color if the sample is stainless steel.

Adhere to the same welding procedure as stated above for repair of the stainless steel material with the following addition.

Prior to welding on the stainless steel material, the crack(s) must be removed by using a carbide rotary file (rotary burr), and stainless steel brushes, both of which are new and have not been used or contaminated on any other materials.

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Table 4
Bare Wire
625	ERNiCrMo-3	EN/RN625	Useful for various dissimilar joints involving nickel alloys, carbon steel, low alloy, and stainless steels. Primarily used on alloys 625, 601, 802, and 9% nickel.

Inspection

Non-Destructive Testing (NDT) for cracks can be performed using two different methods depending upon the material and access to the area in question.

Standard and extreme material can be inspected with either Wet Magnetic Particle Testing (MPT) or dye penetrant inspection also known as liquid penetrant inspection (LPI), or Liquid Penetrant Testing (PT). Refer to the "Crack Detection Methods" section for procedural information.

Stainless steel material and Inconel weld material (and the immediate surrounding area) shall only be inspected using PT.

Unless otherwise designated and approved by the customer, the process shall conform to a widely accepted national or international guideline or standards. Refer to the "Crack Detection Methods" section for more information regarding NDT guidelines and satndards.

The materials and equipment for MPT and PT are available through Magnaflux as well as various other suppliers. Caterpillar recommends using a wet fluorescent continuous process for MPT and a solvent removable visible process for PT. Other types of MPT and PT process / equipment could be used, however shall not be used unless approved or designated by a professional.

Preheating

Precise control of the preheat temperatures is required. Electric-resistance heating blankets, furnace heating, or induction coils, will be used. The following preheat process described in this document was based on the use of a Miller PROHEAT 35 Induction System.

Post Heat

Precise post heating is critical for any welding process performed on the fluid end blocks. After welding, the post heat process prevents stress corrosion cracking and can be accomplished by the same preheating style process.

Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.

Abrasive Grit Blasting

Abrasive grit blasting based on MIL-G-5634.

The nozzle should be held at an angle close to perpendicular with the surface being cleaned.
The nozzle shall be held at 8 - 31 cm (3 - 12 inch) from the surface.
The blast pressure should not exceed 620 kPa (90 psi).

Silicon and aluminum oxide blasting are used for general surface cleaning.

Provide ventilation as required, see AFOSH Standards 161-1 and 161-2.

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Grit blasting produces airborne particulates that can act as respiratory irritants. If inhaled, these particulates can cause serious injury or death. Additionally, the grit from this process can be abrasive to the skin and eyes of the operator and can cause serious injury. If grit blasting is performed manually or outside of a grit blast cabinet, operators must be provided with respiratory protection, face shields, and helmets. Information on face shields and helmets can be found in ANSI/ISEA Z87.1 (American National Standard for Occupational and Educational Eye and Face Protection Devices) and ANSI/ISEA Z89.1 (American National Standard for Industrial Head Protection). Information on the selection, operation, and maintenance of a respiratory device can be found in ANSI/AIHA Z88.2 (Practices for Respiratory Protection) or other local approval authority documentation.

Plastic Media Blasting

Plastic media blasting is a good system for organic coating removal from metal surfaces.

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NOTICE

Do not use plastic media blasting on fiberglass and other composite materials or on metals having a thickness of less than 1.63 mm (0.064 inch) without authorization of the responsible engineering activity.

Shot Peening

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Illustration 3	g03781743
Shot Peen Map (XXX) Areas to be shot peened (OOO) Areas to NOT shot peen

This section defines the requirements for surface peening and texturizing. This process is primarily intended as a galling mitigation technique. A secondary benefit is increased fatigue life when this process is applied to fatigue crack initiation regions.

Note: Shot used for peening shall be glass or ceramic beads.

Shot size shall be in accordance with MIL-S-13165C and the minimum size specified in Table 5.

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Table 5
Minimum Shot Size for Peening
Application	Glass Shot	Ceramic Shot
Threads	0.508 mm (0.02 inch)	0.6096 mm (0.024 inch)
Radii	0.7112 mm (0.028 inch)	0.8382 mm (0.033 inch)

Note: The equipment used shall be in accordance with MIL-S-13165C.

Shot shall meet the requirements of MIL-S-13165. The shot size, shape, and fines removal shall be controlled to yield consistent desirable results.

Autofrettage

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Illustration 4	g03811336
Autofrettage Required Map

Autofrettage is a technique where internal sections of the block are plastically deformed with application of high pressures, resulting in internal compressive residual stresses, similar to work hardening. The goal of this process is to increase the durability of the fluid end.

Currently this process is not required for any of the approved salvage techniques, but will be in future versions. The requirement to re-Autofrettage will be required when the repair heat affected zone moves into the area of the block shown above.

For additional information, contact the Dealer Support Network (DSN).

Buttress Thread Detail

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Table 6
Buttress Thread Detail All Models
Description	Dimension
Thread Data	6 - 3/4 - 4 Buttress Threads 2-B Typical Nine Places
Minimum Minor Diameter	Ø 163.83 mm (6.45 inch)
Maximum Minor Diameter	Ø 164.145 mm (6.4624 inch)
Minimum Pitch Diameter	Ø 167.64 mm (6.600 inch)
Maximum Pitch Diameter	Ø 167.96 mm (6.6127 inch)
Minimum Major Diameter	Ø 172.248 mm (6.7814 inch)
Maximum Major Diameter	Ø 173.086 mm (6.8144 inch)

Machine first and last thread back to full width.

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Illustration 5	g03779037
Typical 6-3/4-4 inch Buttress

The buttress thread is suitable for use in liquid applications and is used extensively in oil field equipment. The threads provide a powerful one-way parallel axis force allowing for tightly sealed joints. These joints can be removed and tensioned quickly and with little effort.

This style of thread is utilized in four areas of the fluid end, the section cover bore, discharge cover bore, and the packing bore. These bores use the same thread size and detail.

Drawing Dimensions

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Table 7
Drawing Dimensions All Models
Description	Dimension
Break Sharp Corners	0.381 mm (0.015 inch)
Fillet Radii	0.762 ± 0.127 mm (0.030 ± 0.005 inch)
Concentricity	0.254 mm (0.010 inch) FIM
Squareness	0.254 mm in 254 m (0.010 inch in 10 feet)
Parallelism	0.254 mm in 254 m (0.010 inch in 10 feet)
RFS except when modified
Description	Dimensional Tolerance
Fractions	± 1/16
X.X	± 0.38100 mm (0.015 inch)
X.XX	± 0.254 mm (0.01 inch)
X.XXX	± 0.127 mm (0.005 inch)
Angle	± 0° - 30'
Surface RMS	125

Any given dimensions or Illustrations in this guideline will follow the information provided in Table 7.

Unless otherwise stated, the tolerances in Table 7 should be applied to all dimensions.

Location - Exterior Body Damage

Exterior damage can be acceptable to areas of the block that are not mating surfaces or sealing surfaces. Exterior damage will need to be repaired if located in the areas stated above.

Repair - Damaged Fluid End Discharge Flange Thread

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Illustration 6	g03831528
Discharge Port

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Table 8
Discharge Port Dimensions All Models
Location	WS223 STD WS255 STD	WS223XD WS223 SS WS255 XD WS255 SS	WS273 XD WS305 XD
A	425.45 mm (16.75 inch)	435.1 mm (17.13 inch)	435.1 mm (17.13 inch)
B	577.85 mm (22.75 inch)	590.55 mm (23.25 inch)	590.55 mm (23.25 inch)
C	238.25 mm (9.38 inch)	250.95 mm (9.88 inch)	250.95 mm (9.88 inch)
D	298.45 mm (11.75 inch)	298.45 mm (11.75 inch)	298.45 mm (11.75 inch)
E	374.65 mm (14.75 inch)	374.65 mm (14.75 inch)	374.65 mm (14.75 inch)
F	485.9 mm (19.13 inch)	498.6 mm (19.63 inch)	498.6 mm (19.63 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

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Illustration 7	g03832790
Discharge Port

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Table 9
Discharge Port Dimensions All Models
Location	WS243 XD, WS243 SS, WS275 XD, WS275 SS
A	514.35 mm (20.25 inch)
B	676.4 mm (26.63 inch)
C	257.3 mm (10.13 inch)
D	358.9 mm (14.13 inch)
E	143.0 mm (5.63 inch)
F	422.4 mm (16.63 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

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Illustration 8	g03832806
Discharge Port

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Table 10
Discharge Port Dimensions All Models
Location	WS253 XD, WS253 SS
A	528.32 mm (20.8 inch)
B	693.42 mm (27.3 inch)
C	263.652 mm (10.38 inch)
D	374.65 mm (14.75 inch)
E	114. mm (4.5 inch)
F	400.05 mm (15.75 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the flange area of block with abrasive blasting or with 180 grit sandpaper.
Ensure that all paint is removed from the surrounding area.
Remove all excess debris from the block with compressed air.
Using a 29/32 inch drill bit, drill out damaged thread (G).
Plug-weld the drilled hole. Use the same base material as the fluid end.
Note: Perform plug welding using the same preheating/post heating slow cooling process as detailed later in the document.
After weld finishes cooling, blend surfaces.
Using a 0.88 x 1.5 inch drill bit, redrill hole (G).
Using a 1-8 UNC Tap, Tap depth 25.4 - 31.75 mm (1.00 - 1.25 inch) retap hole (G).
Clean threaded hole and surrounding area with compressed air.

Repair - Damaged Suction Manifold Bolt Threads

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Illustration 9	g03744590
Bottom View of Suction Flange

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Table 11
Suction Flange Dimensions All Models
Location	WS223 STD, WS223 XD, WS223 SS
A	101.6 mm (4.0 inch)
B	304.8 mm (12.0 inch)
C	88.9 mm (3.5 inch)
D	177.8 mm (7.0 inch)
E	Ø 19.558 mm (0.77 inch) x 7/8 - 9 UNC - 12 places

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Illustration 10	g03832861
Bottom View of Suction Flange

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Table 12
Suction Flange Dimensions All Models
Location	WS255 STD, WS255 XD, WS255 SS	WS273 XD, WS305 XD
A	152.4 mm (6.0 inch)	101.6 mm (4.0 inch)
B	254.0 mm (10.0 inch)	330.2 mm (13.0 inch)
C	88.9 mm (3.5 inch)	88.9 mm (3.5 inch)
D	177.8 mm (7.0 inch)	177.8 mm (7.0 inch)
E	Ø 19.558 mm (0.77 inch) x 7/8- 9 UNC - 20 places	Ø 19.558 mm (0.77 inch) x 7/8- 9 UNC - 20 places

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Illustration 11	g03832889
Bottom View of Suction Flange

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Table 13
Suction Flange Dimensions All Models
Location	WS243 XD, WS243 SS, WS275 XD, WS275 SS
A	165.1 mm (6.5 inch)
B	266.7 mm (10.5 inch)
C	82.55 mm (3.25 inch)
D	165.1 mm (6.5 inch)
E	5/8 - 11 UNC - 20 places

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Illustration 12	g03832901
Bottom View of Suction Flange

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Table 14
Suction Flange Dimensions All Models
Location	WS253 XD, WS253 SS
A	101.6 mm (4.0 inch)
B	304.8 mm (12.0 inch)
C	88.9 mm (3.5 inch)
D	177.8 mm (7.0 inch)
E	Ø 19.558 mm (0.77 inch) x 7/8- 9 UNC - 12 places

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the flange area of block with abrasive blasting or with 180 grit sandpaper.
Ensure that all paint is removed from the surrounding area.
Remove all excess debris from the block with compressed air.
Using a 1.0 inch drill bit, drill out damaged thread (E).
Plug-weld the drilled hole. Use the same base material as the fluid end.
Note: Perform plug welding using the same preheating/post heating slow cooling process as detailed later in this document.
After weld finishes cooling, blend surfaces.
Using a 0.77 inch drill bit, redrill hole (E) 38.1 mm (1.5 inch) deep.
Note: For WS243, WS245: Use a .53 inch drill bit, redrill hole (E) 35.56 mm (1.4 inch) deep.
Using a 7/8-9 UNC Tap, Tap depth 25.4 mm (1.0 inch) minimum, retap hole (E).
Note: For WS243, WS245: Using a 5/8-11 UNC Tap, Tap depth 25.4 mm (1.0 inch) minimum, retap hole (E).
Clean threaded hole and surrounding area with compressed air.

Repair - Damaged Discharge Stud

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Illustration 13	g03831528
Discharge Port

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Table 15
Discharge Port Dimensions All Models
Location	WS223 STD WS255 STD	WS223XD WS223 SS WS255 XD WS255 SS	WS273 XD WS305 XD
A	425.45 mm (16.75 inch)	435.1 mm (17.13 inch)	435.1 mm (17.13 inch)
B	577.85 mm (22.75 inch)	590.55 mm (23.25 inch)	590.55 mm (23.25 inch)
C	238.25 mm (9.38 inch)	250.95 mm (9.88 inch)	250.95 mm (9.88 inch)
D	298.45 mm (11.75 inch)	298.45 mm (11.75 inch)	298.45 mm (11.75 inch)
E	374.65 mm (14.75 inch)	374.65 mm (14.75 inch)	374.65 mm (14.75 inch)
F	485.9 mm (19.13 inch)	498.6 mm (19.63 inch)	498.6 mm (19.63 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

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Illustration 14	g03832790
Discharge Port

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Table 16
Discharge Port Dimensions All Models
Location	WS243 XD, WS243 SS, WS275 XD, WS275 SS
A	514.35 mm (20.25 inch)
B	676.4 mm (26.63 inch)
C	257.3 mm (10.13 inch)
D	358.9 mm (14.13 inch)
E	143.0 mm (5.63 inch)
F	422.4 mm (16.63 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

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Illustration 15	g03832806
Discharge Port

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Table 17
Discharge Port Dimensions All Models
Location	WS253 XD, WS253 SS
A	528.32 mm (20.8 inch)
B	693.42 mm (27.3 inch)
C	263.652 mm (10.38 inch)
D	374.65 mm (14.75 inch)
E	114. mm (4.5 inch)
F	400.05 mm (15.75 inch)
G	Ø 22.35 mm (0.88 inch) x 38.1 mm (1.5 inch)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Preheat damaged stud with an oxyacetylene torch to remove Loctite
If threads are usable:
1. Use two nuts together on the stud and back the stud out with a wrench.
If the threads are not usable:
1. Use a large pipe wrench to back out the stud.
Once damaged stud is removed, inspect threaded hole for damage.
Before installing new stud, apply Loctite to the first half of the stud.
Drive stud into block using a Bully Dog Stud Driver (16B - 8-12).

Repair - Damaged Lifting Thread

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Illustration 16	g03831556
Top View

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Table 18
Top View Fluid End Dimensions All Models
Location	WS223, WS223 XD, WS223 SS
A	304.8 mm (12.0 inch)
B	260.35 mm (10.25 inch)
C	1 inch - 8, 2 inches Deep

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Illustration 17	g03834033

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Table 19
Top View Fluid End Dimensions All Models
Location	WS225
A	762.0 mm (30.0 inch)
B	260.35 mm (10.25 inch)
C	1 inch - 8, 2 inches Deep

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Illustration 18	g03834398

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Table 20
Top View Fluid End Dimensions All Models
Location	WS255 XD, WS255 SS	WS305 XD
A	762.0 mm (30.0 inch)	990.6 mm (39.0 inch)
B	260.35 mm (10.25 inch)	298.45 mm (11.75 inch)
C	1 inch - 8, 2 inches Deep	1 1/4 inch - 7, 2.5 inches Deep

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Illustration 19	g03834410

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Table 21
Top View Fluid End Dimensions All Models
Location	WS273 XD
A	330.2 mm (13.0 inch)
B	298.45 mm (11.75 inch)
C	1 inch - 8, 2 inches Deep

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Illustration 20	g03834420

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Table 22
Top View Fluid End Dimensions All Models
Location	WS243 XD, WS243 SS
A	843.28 mm (33.2 inch)
B	177.8 mm (7.0 inch)
C	1 inch - 8, 2 inches Deep

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Illustration 21	g03834427

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Table 23
Top View Fluid End Dimensions
Location	WS275 XD, WS275 SS
A	800.1 mm (31.5 inch)
B	177.8 mm (7.0 inch)
C	1 inch - 8, 2 inches Deep

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Illustration 22	g03834432

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Table 24
Top View Fluid End Dimensions All Models
Location	WS253 XD, WS253 SS
A	304.8 mm (12.0 inch)
B	158.75 mm (6.25 inch)
C	1 inch - 8, 2 inches Deep

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the flange area of block with abrasive blasting or 180 grit sandpaper.
Ensure that all paint is removed from the surrounding area.
Remove all excess debris from the block with compressed air.
Using a 1 - 1/4 inch drill bit, redrill hole drill out damaged thread.
Note: For WS305 XD: Using a 1-35/64 inch drill bit, drill out damaged thread.
Plug weld the drilled hole. Use the same base material as the fluid end.
Note: Perform plug welding using the same preheating/post heating slow cooling process as detailed later in this document.
After weld finishes cooling, blend surfaces.
Using a .88 inch drill bit, redrill hole (C) 63.5 mm (2.5 inch) deep.
Note: For WS305 XD, use a 1.11 inch drill bit, redrill hole (C) 76.2 mm (3.0 inch) deep.
Using a 1-8 UNC Tap, Tap depth 50.8 mm (2.0 inch), retap hole (C).
Note: For WS305 XD, use a 1.25 - 7 UNC, Tap depth 63.5 mm (2.5 inch) minimum, retap hole (C).
Clean threaded hole and surrounding area with compressed air.

Location - Mounting Flange

The mounting flange is at the rear of the fluid end. This location is where the power end bolts to the fluid end via the stay rods. Any cracks in this area are considered not repairable.

Note: Tables 25,26, and 27 are provided as a reference only.

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Illustration 23	g03745143
Rear View

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Table 25
Mounting Flange Dimensions All Models
Location	WS223
A	152.4 mm (6.0 inch)
B	609.6 mm (24.0 inch)
C	304.8 mm (12.0 inch)
D	98.552 mm (3.88 inch)
E	104.775 mm (4.125 inch)
F	Ø 45.974 mm (1.81 inch) - 12 places
G	146.05 mm (5.75 inch)
H	292.1 mm (11.5 inch)
J	Ø 45.974 mm (1.81 inch) - two places
K	95.25 mm (3.75 inch)
L	457.2 mm (18.0 inch)

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Illustration 24	g03832921
Rear View

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Table 26
Mounting Flange Dimensions All Models
Location	WS223 XD, WS223 SS	WS273 XD
A	152.4 mm (6.0 inch)	165.1 mm (6.5 inch)
B	609.6 mm (24.0 inch)	660.4 mm (26.0 inch)
C	304.8 mm (12.0 inch)	330.2 mm (13.0 inch)
D	98.552 mm (3.88 inch)	98.55 mm (3.88 inch)
E	104.775 mm (4.125 inch)	114.3 mm (4.5 inch)
F	Ø 45.974 mm (1.81 inch) - 12 places	49.276 mm (1.94 inch) - 12 places
G	146.05 mm (5.75 inch)	171.45 mm (6.75 inch)
H	292.1 mm (11.5 inch)	342.9 mm (13.5 inch)
J	Ø 45.974 mm (1.81 inch) - 2 places	19.05 mm (0.75 inch) - 2 places
K	95.25 mm (3.75 inch)	101.6 mm (4.0 inch)
L	482.6 mm (19.0 inch)	508.0 mm (20.0 inch)

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Illustration 25	g03834460

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Table 27
Mounting Flange Dimensions All Models
Location	WS255, WS255 XD, WS255 SS	WS305 XD
A	127.0 mm (5.0 inch)	165.1 mm (6.5 inch)
B	508.0 mm (20.0 inch)	660.4 mm (26.0 inch)
C	254.0 mm (10.0 inch)	330.2 mm (13.0 inch)
D	98.552 mm (3.88 inch)	98.55 mm (3.88 inch)
E	79.375 mm (3.125 inch)	114.3 mm (4.5 inch)
F	Ø 45.974 mm (1.81 inch) - 20 places	49.276 mm (1.94 inch) - 20 places
G	152.4 mm (6.0 inch)	171.45 mm (6.75 inch)
H	304.8 mm (12.0 inch)	342.9 mm (13.5 inch)
J	Ø 19.05 mm (0.75 inch)	Ø 19.05 mm (0.75 inch)
K	95.25 mm (3.75 inch)	101.6 mm (4.0 inch)
L	660.4 mm (26.0 inch)	838.2 mm (33.0 inch)

Repair - Surface Damage

Surface damage (example: pitting, corrosion) can be repaired if the damage is less than 6.35 mm (0.25 inch) into the entire fluid end, excluding the mounting flange.

The mounting flange may be refaced up to 1.27 mm (0.05 inch) from the original dimension. Damage to the mounting flange greater than 1.27 mm (0.05 inch), contact the DSN for support.

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Illustration 26	g03831592
Side View

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Table 28
Mounting Flange Dimensions All Models
Location	WS223 XD, WS223 SS	WS255 STD	WS255 XD, WS255 SS	WS273 XD, WS305 SS
A	339.852 mm (13.38 inch)	327.152 mm (12.88 inch)	339.852 mm (13.38 inch)	339.852 mm (13.38 inch)
B	139.7 mm (5.5 inch)	139.7 mm (5.5 inch)	139.7 mm (5.5 inch)	139.7 mm (5.5 inch)
C	76.2 mm (3.0 inch)	76.2 mm (3.0 inch)	76.2 mm (3.0 inch)	76.2 mm (3.0 inch)
D	60.452 mm (2.38 inch)	47.752 mm (1.88 inch)	60.452 mm (2.38 inch)	60.452 mm (2.38 inch)
E	158.75 mm (6.25 inch)	158.75 mm (6.25 inch)	158.75 mm (6.25 inch)	209.55 mm (8.25 inch)
F	95.25 mm (3.75 inch)	95.25 mm (3.75 inch)	95.25 mm (3.75 inch)	146.05 mm (5.75 inch)
G	28.7 mm (1.13 inch)	63.5 mm (2.5 inch)	54.102 mm (2.13 inch)	31.75 mm (1.25 inch)
H	339.852 mm (13.38 inch)	339.852 mm (13.38 inch)	339.852 mm (13.38 inch)	339.852 mm (13.38 inch)
J	250.952 mm (9.88 inch)	238.252 mm (9.38 inch)	250.952 mm (9.88 inch)	250.952 mm (9.88 inch)
K	63.5 mm (2.5 inch)	63.5 mm (2.5 inch)	63.5 mm (2.5 inch)	63.5 mm (2.5 inch)
L	319.786 mm (12.59 inch)	342.138 mm (13.47 inch)	319.786 mm (12.59 inch)	319.786 mm (12.59 inch)
M	104.902 mm (4.13 inch)	104.902 mm (4.13 inch)	104.902 mm (4.13 inch)	104.902 mm (4.13 inch)
N	146.05 mm (5.75 inch)	133.35 mm (5.25 inch)	146.05 mm (5.75 inch)	146.05 mm (5.75 inch)
P	279.4 mm (11.0 inch)	266.7 mm (10.5 inch)	279.4 mm (11.0 inch)	279.4 mm (11.0 inch)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the surface area of block with abrasive blasting or with 180 grit sandpaper.
Remove a maximum of 0.381 mm (0.015 inch) from (K) on Table 28.
Note: If damage is greater than 0.381 mm (0.015 inch), contact the DSN for repair support.
Note: Ensure to machine entire damaged face.
Note: Do not create steps in material.
Remove all excess debris from the block with compressed air.
Finish machined surface with 400 grit sandpaper.

Location - Suction Cover Bore

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Illustration 27	g03834480
Suction Cover Bore

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Table 29
Suction Cover Bore Dimensions All Models
Location	WS223 WS255 (4in Plunger)	WS223 WS255 (4.5in and larger Plunger)	WS223 XD, SS WS255 XD, SS WS273 XD, SS WS305 XD, SS
A	3.302 mm (0.13 inch)	3.302 mm (0.13 inch)	3.302 mm (0.13 inch)
B	68.326 mm (2.69 inch)	68.326 mm (2.69 inch)	79.5 mm (3.13 inch)
C	9.652 mm (0.38 inch) x 15°	9.652 mm (0.38 inch) x 15°	9.652 mm (0.38 inch) x 15°
D	9.652 mm (0.38 inch)	9.652 mm (0.38 inch)	9.652 mm (0.38 inch)
E	6-3/4-4 Buttress Threads	6-3/4-4 Buttress Threads	6-3/4-4 Buttress Threads
F	Ø 120.7 ± 0.025 mm (4.752 ± 0.001 inch)	139.725 ± 0.025 mm (5.501 ± 0.001 inch)	Ø 120.7 ± 0.025 mm (4.752 ± 0.001 inch)
G	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)
H	Ø 174.752 mm (6.88 inch)	Ø 174.752 mm (6.88 inch)	Ø 174.752 mm (6.88 inch)

Repair - Crack in suction cover threads

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the fluid end block with abrasive blasting using a glass media.
Remove all excess abrasive blasting media from the block with compressed air.
Preheat the block to 350 - 390° C (660-730° F) using one of the methods stated in the "Notes" section.
Weld worn/damaged area using an Inconel 625 wire with a two-layer minimum with a depth of 6.35 mm (0.25 inch).
After the welding is complete, hold the block at 350 - 390° C (660-730° F) for 3 hours.
Note: Do not exceed 480° C (900° F) during any time with either induction Preheat, post heat, or welding interpass temperatures.
Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.
Once the block has cooled, mount the block on the machine deck.
Remove excess welded material from the bore.
Machine bore I.D. (G) back to 163.982 ± 0.152 mm (6.456 ± 0.006 inch).
After the internal machining is completed, inspect for cracks and tooling damage.
Note: If a crack or other damage is found, stop the repair and contact the DSN.
Proceed with cutting the 6-3/4-4 Buttress thread (E) into the newly machined suction bore.
After thread is cut, use a profile gauge to inspect the thread.
All non-sealing surfaces (including buttress threads) should be reshot peened to relieve surface tension.

Repair - Crack Leading into Intersecting Bore

Cracks in the intersecting bore that propagate from suction bore, discharge bore, or packing bore are currently not repairable. Illustration 28 is included for reference only.

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Illustration 28	g03834488
Intersecting Bore

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Table 30
Intersecting Bore Dimensions All Models
Location	4 Series Valve	5 Series Valve
A	Ø 94.59 mm (3.724 inch)	Ø 115.087 mm (4.53 inch) Bore
B	If there is a transition, blend	Blend 139.7 mm (5.5 inch) Suction Cover bore into 4-7/8 inch Plunger Bore with 15° feather/taper
C	14.22 ± 1.52 mm (0.56 ± 0.06 inch)	14.22 ± 1.52 mm (0.56 ± 0.06 inch)
D	Ø 120.65 mm (4.75 inch)	Ø 136.652 mm (5.38 inch)

Location - Suction Seat Deck

Suction seat damage is commonly caused by poor maintenance with debris being left on the taper bore when a new seat is fitted in.

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Illustration 29	g03834572
Suction Seat

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Table 31
Suction Seat Dimensions All Models
Location	4 Series Valve	5 Series Valve
A	Ø 120.65 mm (4.75 inch)	Ø 136.652 mm (5.38 inch)
B	44.45 mm (1.75 inch)	44.45 mm (1.75 inch)
C	76.2 mm (3.0 inch)	60.452 mm (2.38 inch)
D	Ø 95.352 mm (3.754 inch)	Ø 115.087 mm (4.53 inch) Bore
E	Ø 130.302 mm (5.13 inch)	Ø 152.4 mm (6.0 inch)

Repair - Surface Damage to Seat Deck

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the fluid end block with abrasive blasting using a glass media.
Remove all excess abrasive blasting media from the block with compressed air.
Preheat the block to 350 - 390° C (660-730° F) using one of the methods stated in the "Notes" section.
Weld worn/damaged area using an Inconel 625 wire with a two-layer minimum with a depth of 6.35 mm (0.25 inch).
After the welding is complete, hold the block at 350 - 390° C (660-730° F) for 3 hours.
Note: Do not exceed 480° C (900° F) during any time with either induction Preheat, post heat, or welding interpass temperatures.
Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.
Once the block has cooled, mount the block on the machine deck.
Remove excess welded material from the bore.
Machine bore I.D. (E) based on Table 31.
After the internal machining is completed, inspect for cracks and tooling damage.
Note: If a crack or other damage is found, stop the repair and contact the DSN.
Machine taper bore (B) at 19.05 mm (0.75 inch) per 0.305 m (1.0 ft) on diameter.
All non-sealing surfaces (including buttress threads) should be reshot peened to relieve surface tension.

Repair - "Washout" Style Damage to Taper Bore

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Illustration 30	g06337063
Example of suction side of 4 and 5 series valves.

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Table 32
Taper Seat Dimensions All Models
Location	4 Series Valve	5 Series Valve
A	Ø 130.3 ± 0.3 mm (5.13 ± 0.01 inch)	Ø 114.78 ± 0.46 mm (4.519 ± 0.018 inch)
B	Ø 97.358 ± 0.025 mm (3.833 ± 0.001 inch)	Ø 117.91 ± 0.03 mm (4.642 ± 0.001 inch)
C	Ø 94.28 ± 0.46 mm (3.712 ± 0.018 inch)	Ø 114.17 ± 0.46 mm (4.495 ± 0.018 inch)
D	3.18 ± 0.51 mm (0.125 ± 0.020 inch) SUCTION SIDE ONLY	3.18 ± 0.51 mm (0.125 ± 0.020 inch) SUCTION SIDE ONLY
E	12.7 ± 0.5 mm (2X R 0.50 ± 0.02 inch) SUCTION SIDE ONLY	12.7 ± 0.5 mm (2X R 0.50 ± 0.02 inch) SUCTION SIDE ONLY
F	0.8 ± 0.3 mm 45° (0.03 ± 0.01 inch 45°)	0.5 ± 0.3 mm 45° (0.02 ± 0.01 inch 45°)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the fluid end block with abrasive blasting using a glass media.
Remove all excess abrasive blasting media from the block with compressed air.
Preheat the block to 350 - 390° C (660-730° F) using one of the methods stated in the "Notes" section.
Weld worn/damaged are using an Inconel 625 wire with a two-layer minimum with a depth of 6.35 mm (0.25 inch).
After the welding is complete, hold the block at 350 - 390° C (660-730° F) for 3 hours.
Note: Do not exceed 480° C (900° F) during any time with either induction Preheat, post heat, or welding interpass temperatures.
Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.
Once the block has cooled, mount the block on the machine deck.
Remove excess welded material from the bore.
Machine taper bore (D) at 19.05 mm (0.75 inch) per 0.305 m (1.0 ft).
After the internal machining is completed, inspect for cracks and tooling damage.
Note: If a crack or other damage is found, stop the repair and contact the DSN.
All non-sealing surfaces (including buttress threads) should be reshot peened to relieve surface tension.
Note: Make sure to seal off taper bore from shot peening process.

Location - Discharge Cover

The discharge covers or bores are at the top of the fluid end. This bore utilizes the same buttress thread connection as the other bores of the block.

Repair - Damage to Discharge Cover Bore

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Illustration 31	g06345468
Example of discharge side of 4 and 5 series valves.

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Table 33
Discharge Bore Dimensions All Models
Location	4 Series Valve	5 Series Valve
A	Ø 174.75 ± 0.3 mm (6.88 ± 0.01 inch)	Ø 174.8 ± 0.3 mm (6.88 ± 0.01 inch)
B	6.75-4 Buttress Thread	6.75-4 Buttress Thread
C	4.8 ± 0.3 mm (0.19 ± 0.01 inch)	4.8 ± 0.3 mm (0.19 ± 0.01 inch)
D	64 ± 0.3 mm (2.50 ± 0.01 inch)	65.0 ± 0.3 mm (2.56 ± 0.01 inch)
E	10 ± 0.3 mm (0.4 ± 0.01 inch)	10 ± 0.3 mm (0.40 ± 0.01 inch)
F	97.36 ± 0.03 mm (3.833 ± 0.001 inch)	Ø 139.73 ± 0.03 mm (5.501 ± 0.001 inch)
G	212.9 + 3.8 - 0.0 mm (8.38 + 0.15 -0.00 inch)	200.2 + 3.8 - 0.0 mm (7.88 + 0.15 -0.00 inch)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the fluid end block with abrasive blasting using a glass media.
Remove all excess abrasive blasting media from the block with compressed air.
Preheat the block to 350 - 390° C (660-730° F) using one of the methods stated in the "Notes" section.
Weld worn/damaged area using an Inconel 625 wire with a two-layer minimum with a depth of 6.35 mm (0.25 inch).
After the welding is complete, hold the block at 350 - 390° C (660-730° F) for 3 hours.
Note: Do not exceed 480° C (900° F) during any time with either induction Preheat, post heat, or welding interpass temperatures.
Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.
Once the block has cooled, mount the block on the machine deck.
Remove excess welded material from the bore.
Machine bore ID (B) back to 163.982 ± 0.152 mm (6.456 ± 0.006 inch).
After the internal machining is completed, inspect for cracks and tooling damage.
Note: If a crack or other damage is found, stop the repair and contact the DSN.
Proceed with cutting the 6-3/4-4 Buttress thread (E) into the newly machined suction bored.
After the thread is cut, use a profile gauge to inspect the thread.
All non-sealing surfaces (including buttress threads) should be reshot peened to relieve surface tension.
Note: Make sure to seal off taper bore from shot peening process.

Location - Discharge Rail

The Discharge rail is under high pressure during operation and is a common area to find damage. Refer to Illustration 30.

Location - Packing Bore

Repair - Wash out in Packing Bore

The technique used to salvage the packing bore is replacing the washed out material with layers of welded metal then machining the undersized bore in the fluid block back to a specified diameter.

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Illustration 32	g03742703
Washout extends from packing bore

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Illustration 33	g03742718
Enlarged view of Washout

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Illustration 34	g03745440
Packing Bore

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Table 34
Packing Bore Dimensions All Models
Location	4.0in Plunger (All Models)	4.5in Plunger (All Models)	5.0in Plunger (All Models)	5.5in Plunger (All Models)
A	Ø 174.752 mm (6.88 inch)	Ø 174.752 mm (6.88 inch)	Ø 174.752 mm (6.88 inch)	Ø 174.752 mm (6.88 inch)
B	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)	Ø 163.982 ± 0.152 mm (6.456 ± 0.006 inch)
C	Ø 127.025 mm (5.001 inch)	Ø 139.725 ± 0.025 mm (5.501 ± 0.001 inch)	Ø 152.425 mm (6.001 inch)	Ø 165.125 mm (6.501 inch)
D	3.175 mm (0.125 inch)	3.175 mm (0.125 inch)	3.175 mm (0.125 inch)	3.175 mm (0.125 inch)
E	9.652 mm (0.38 inch)	9.652 mm (0.38 inch)	9.652 mm (0.38 inch)	9.652 mm (0.38 inch)
F	133.477 ± 0.127 mm (5.255 ± 0.005 inch)	133.477 ± 0.127 mm (5.255 ± 0.005 inch)	133.477 ± 0.127 mm (5.255 ± 0.005 inch)	133.477 ± 0.127 mm (5.255 ± 0.005 inch)
G	6-3/4-4 inch Buttress Thread	6-3/4-4 inch Buttress Thread	6-3/4-4 inch Buttress Thread	6-3/4-4 inch Buttress Thread
H	1.524 mm (0.06 inch)	1.524 mm (0.06 inch)	1.524 mm (0.06 inch)	1.524 mm (0.06 inch)

Procedure

Note: Before starting any repair, confirm the material of the fluid end. If the fluid end is stainless steel, follow the stainless note in the "Notes" section.

Start by cleaning the fluid end block with abrasive blasting using a glass media.
Remove all excess abrasive blasting media from the block with compressed air.
Preheat the block to 350 - 390° C (660-730° F) using one of the methods stated in the "Notes" section.
Weld worn/damaged area using an Inconel 625 wire with a two-layer minimum with a depth of 6.35 mm (0.25 inch).
After the welding is complete, hold the block at 350 - 390° C (660-730° F) for 3 hours.
Note: Do not exceed 480° C (900° F) during any time with either induction Preheat, post heat, or welding interpass temperatures.
Following post heating, slow cooling is required by wrapping in heat resistant blankets or insulation and allowing to cool to room temperature in a still air environment.
Once the block has cooled, mount the block on the machine deck.
Remove excess welded material from the bore.
Machine bore ID (B) back to 163.982 ± 0.152 mm (6.456 ± 0.006 inch), based on Table 34.
After the internal machining is completed, inspect for cracks and tooling damage.
Note: If a crack or other damage is found, stop the repair and contact the DSN.
Proceed with cutting the 6-3/4-4 Buttress thread (G) into the newly machined packing bore.
After the thread is cut, use a profile gauge to inspect the thread.
All non-sealing surfaces (including buttress threads) should be reshot peened to relieve surface tension.

Crack Detection Methods

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NOTICE

Regardless of which crack detection method is used, it is important that the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

There are three major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), and Wet Magnetic Particle Testing (MPT).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, and Wet are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 35 for advantages and disadvantages and Table 36 for standards and requirements for these NDT methods.

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Table 35
Crack Detection Methods Advantages vs. Disadvantages
Detection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least Expensive - Detects most damaging defects. - Immediate Results - Minimum part preparation	- Limited to surface-only defects. - Requires inspectors to have broad knowledge of welding and fabrication in addition to Non-Destructive Testing (NDT).
Liquid Penetrant Testing (PT)	- Inexpensive - Minimal Training - Portable - Works on nonmagnetic material.	- Least Sensitive - Detects surface cracks only. - Rough or porous surfaces interfere with test
Wet Magnetic Particle (MPT)	- More sensitive than Liquid Penetrant Testing (PT). - Detects subsurface as much as 0.13 mm (0.005 inch).	- Requires power for light. - Works on magnetic material only. - Liquid composition and agitation must be monitored.

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Table 36
Applicable Crack Detection Standards
Detection Method	Standard	Acceptance Criteria	Minimum Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A
Magnetic Particle Testing (MPT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	EN-ISO 9712 ANSI-ASNT SNT-TC-1A

Visual Surface Inspection (VT)

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Illustration 35	g06124166
Example of Visual Surface Inspection (VT) Tooling (A) Flashlight (or adequate light source) (B) Magnifying Glass (C) Tape Measure (or other measuring device) (D) Inspection Mirror

Refer to Tooling and Equipment Table 3 for part numbers.

Components and welds that are to be tested using PT, MPT, or UT shall first be subject to a Visual Surface Inspection (VT). VT is often the most cost-effective inspection method and requires little equipment as seen in Illustration 35. Personnel performing VT shall either be trained to a company standard or have sufficient experience and knowledge regarding the components being inspected. Personnel performing VT shall take routine eye exams.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do the job.
Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.
Penetrating Oil: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.
Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrating oil indications.
Wire Brush: Removes dirt and paint.
Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 36	g06103795
Typical example of pre-cleaning the testing area.

Preclean the area to be tested. Spray on cleaner/ remover to loosen any scale, dirt, or any oil. Wipe the area to be tested with a solvent dampened cloth to remove remaining dirt and allow the area to dry. Remove paint where there are visible cracks using paint remover or a wire brush.
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Illustration 37 g06103803

Typical example of applying penetrating oil to areas to be tested.
Apply penetrant by spraying to the entire area to be tested. Allow 10 to 15 minutes for penetrant to soak. After the penetrating oil has been allowed to soak, remove the excess penetrating oil with clean, dry wipe.
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Illustration 38 g06103816

Typical example of removing penetrating oil with a cloth.
The last traces of penetrating oil should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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Illustration 39 g06103820

Typical example of applying the developer.
Before using developer, ensure that the developer is mixed thoroughly by shaking the container. Hold the container approximately 203 - 305 mm (8.0 - 12.0 inch) away from the testing area. Apply an even, thin layer of developer over the testing area. A few thin layers are a better application method than one thick layer.
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Illustration 40 g06084042

Typical example of cracks found during Liquid Penetrant Testing (PT).
Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 40. Clean the area of application of the developer with solvent cleaner.

Wet Magnetic Particle Testing (MPT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

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Illustration 41	g06085937
(A) Indications shown by Wet Magnetic Particle Testing (MPT). (B) Electromagnetic Yoke (D) Ultraviolet Lamp

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Illustration 42	g06003178
Pear Shaped Centrifuge Tube

Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.
Concentration:
1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.
2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) divisions, refer to Illustration 42. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.
3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.
4. The oil shall have the following characteristics:
  - Low viscosity not to exceed 5 mm²/_s (5 cSt) at any temperature at which the vehicle is to be used.
  - Low inherent fluorescence and be non-reactive.
5. The conditioning agents used in the conditioned water shall have the following characteristics:
  - Impart good wetting characteristics and good dispersion.
  - Minimize foaming and be non-corrosive.
  - Low viscosity shall not exceed a maximum viscosity of 5 mm²/_s (5 cSt) at 38° C (100° F).
  - Non-fluorescent, non-reactive, and odorless.
  - Alkalinity shall not exceed a pH of 10.5.
Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.
Apply the magnetic field using the yoke against the surface in the area to be inspected.
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Illustration 43 g03536210
For case hardened and ground surfaces:
- Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 43 for an example of yoke placement.
Visually inspect for indications of discontinuities using the proper illumination.
Record the size and shape of any discontinuities found.