WS223, WS223 SS, WS223 XD, WS255, WS255 SS, WS255 XD, WSP223, WSP255, WSF223, WSF223 SS, WSF223 XD, WSF255, WSF255 SS and WSF255 XD Well Stimulation Pumps Caterpillar

Removal Procedure

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Illustration 1	g03366605

1. Disconnect hose assembly (1). Remove fitting (2).

2. Remove bolts (3) and cover (4).

3. Remove bolts (5) and cover (6).
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   Illustration 2	g03366606

4. Attach a suitable lifting device to cover (7). The weight of cover (7) is approximately 57 kg (126 lb). Remove bolts (8), cover (7), and the gasket. Repeat for the opposite side.
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   Illustration 3	g03366608

5. Remove crankshaft housing (9) and the gasket.

6. Remove pinion housing (11) and the gasket.

7. Remove safety wire (10) and fitting (12).
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   Illustration 4	g03371404

8. Remove set screw (13).
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   Table 2

   Approximate weight of bull gear (16)
   Sales Model	Approximate Weight
   WS223 WS223 SS WS223 XD	400 kg (882 lb)
   WS255 WS255 SS WS255 XD	370 kg (815 lb)

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   Illustration 5	g03371405

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   Illustration 6	g03371408

9. Use Tooling (A) to remove key (14). Remove key (14).

10. Use Tooling (B) and a suitable lifting device to remove bull gear (16). Refer to Table 2 for the approximate weight of bull gear (16). Remove bolts (15). Install Tooling (C). Remove bull gear (16). Repeat Step 5 through Step 10 for the opposite side.

Installation Procedure

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Illustration 7	g03392136

1. Use Tooling (B) and a suitable lifting device to install bull gear (16). Refer to Table 4 for the approximate weight of bull gear (16). Install bull gear (16). Install the off put side bull gear (16).

   Note: If the bull gear has a counter weight, Install off put side bull gear (16) with counter weight (17) in the 6 O'clock position.

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   Illustration 8	g03392769

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   Illustration 9	g03392781

   Note: When inserting a straight key (14) into the off-put side keyway, make sure the straight key (14) is installed correctly. The crankshaft key way and the bull gear key way should be aligned. Straight key (14) and the keyway is shaped for straight key (14) to be installed in one direction only.

2. Apply Tooling (D) to key (14). Install key (14).

3. Apply Tooling (E) to the threads of bolts (15). Install bolts (15). Tighten bolts (15) to a torque of 1383 N·m (1020 lb ft).
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   Illustration 10	g03371404

4. Apply Tooling (E) to the threads of set screw (13). Install set screw (13). Tighten set screw (13) to a torque of 61 N·m (45 lb ft).
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   Table 5

   Approximate weight of bull gear (16)
   Sales Model	Approximate Weight
   WS223 WS223 SS WS223 XD	400 kg (882 lb)
   WS255 WS255 SS WS255 XD	370 kg (815 lb)

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   Illustration 11	g03392136

   Note: Start the gear keyway 9.53 mm (0.375 inch) behind the crankshaft keyway to allow for proper alignment when installing the drive side bull gear. The bull gear will rotate clockwise during installation. Confirm the keyways align.

5. Use Tooling (B) and a suitable lifting device to install bull gear (16). Refer to Table 5 for the approximate weight of bull gear (16). Install the drive side bull Gear (16).

   Note: If the bull gear has a counter weight, Install drive side bull gear (16) with counter weight (17) in the 6 O'clock position.

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   Illustration 12	g03393603

6. Install two of the four bolts (15). Tighten bolts (15) to a torque of 1383 N·m (1020 lb ft).

7. Loosen each bolt (15) one at a time and retighten to hand tight only.
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   Table 6

   Crankshaft total float travel measurement
   Sales Model	Crankshaft total float travel measurement
   WS223 WS223 SS WS223 XD	0.48 to 1.49 mm (0.019 to 0.059 inch)
   WS255 WS255 SS WS255 XD	0.25 to 0.89 mm (0.010 to 0.035 inch)

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   Illustration 13	g03393628

8. Use Tooling (F) to check the crankshaft total float travel measurement. Refer to Table 6 for the crankshaft total float travel measurement. Move the crankshaft back half the distance of the crankshaft total float travel measurement, this is to center the crankshaft.

   Note: If the crankshaft total float travel measurement is out of tolerance, refer to Disassembly and Assembly, "Crankshaft (Pump) - Remove and Install" for crankshaft total float travel measurement procedure.

9. Use Tooling (G) to center the pinion shaft. Measure the distance from the face of the pinion gear to the face of the crankshaft gear. Repeat for the opposite side and record measurement. The measure from side to side should be equal.

10. Use Tooling (H) to preload the pinion teeth and gear teeth on both sides simultaneously. Use the thickest possible feeler gauge when preloading. The same size feeler gauge must be used on both sides.

11. Use a 0.038 mm (0.0015 inch) gauge to confirm both sides are loaded. When proper load is present, the 0.038 mm (0.0015 inch) feeler gauge should NOT fit between the pinion teeth and gear teeth.

12. After confirming load is present on the Drive side and off put side, use Tooling (H) to measure the offset in the drive side keyway. The offset will indicate what offset key to install in keyway.
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    Illustration 14	g03493605

13. Apply Tooling (D) to key (14). Install key (14) half way.

14. Remove Tooling (H) from the pinion and gear teeth. Check for load on both sides simultaneously.

15. Once load is present on both sides, Apply Tooling (E) to bolts (15) and torque to 1383 N·m (1020 lb ft).

16. Fully install key (14). If using an offset key, the key will protrude the key way approximately half inch when fully installed. Apply Tooling (E) to the threads of set screw (13). Install set screw (13). Tighten set screw to a torque of 61 N·m (45 lb ft).
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    Illustration 15	g03366608

17. Install safety wire (10) and fitting (12).

18. Install pinion housing (11) and the gasket.

19. Install crankshaft housing (9) and the gasket.
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    Illustration 16	g03366606

20. Apply Tooling (J) to the treads of bolts (8). Position cover (7) and the gasket. Install bolts (8).
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    Illustration 17	g03366605

21. Apply Tooling (E) to the threads of the bolts (5). Install cover (6) and bolts (5).

22. Apply Tooling (E) to the threads of the bolts (3). Install cover (4) and bolts (3).

23. Install fitting (2). Connect hose assembly (1).

24. Repeat Step 17 through Step 20 for the off put side.

25. Repeat Step 22 and Step 24 for the right side (off put side).