12
Gear End Disassembly
NOTE: The manifold (29) weep seal housing (48) and spacer sleeve (26A) must be removed. See above
for directions.
15. Remove the crankcase cover screws (9). Inspect the crankcase cover o-ring (4) for wear. Replace if
necessary.
16. Inspect the dipstick (5) vent hole for signs of clogging. Clean if necessary.
17. To remove the crankshaft (18), first remove the bearing cover plates (12). Remove the key (19).
18. With a 5 mm allen wrench remove the connecting rod screws (21) and rear portion of connecting rod
assemblies (20). Push the connecting rod (20) and plunger rod (22) down as far as possible into the
crankcase housing.
19. Hold the pump rear assembly with a wooden fixture, or other suitable device, in order to secure it while
removing the crankshaft (18). Using a plastic mallet, tap the crankshaft from one side while turning it
from the other side. The turning insures that during this sequence the crankshaft does not become
wedged against the front portion of the connecting rods (20). The far side bearing (15) will remain in the
crankcase (1). When free, the crankshaft can be removed by hand. The opposite side crankshaft seal (14)
will be removed by this procedure.
It is important that you turn the crankshaft (18) constantly while
tapping from the opposite end to avoid any binding. The crankshaft bearing (15) remains on the
crankshaft as it is removed.
If necessary, use a bearing puller to remove the crankshaft bearing (15).
20. Remove the front portion of the connecting rods (20) and plunger base assembly (22) from the rear of the
pump by pulling straight out of the crankcase crosshead guides.
Notice that the connecting rod (20)
halves are numbered or colored. Connecting rods must be positioned with their numbers or colors
on the upper left-hand side, in the same numerical sequence as when they were removed.
21. Using a dowel and a rubber mallet, tap the oil seals (26) out from the rear of crankcase (1). The area onto
which the oil seal rests should be clean and dry. Put a small drop of loc-tite on the oil seals and place into
crankcase with lips facing the rear of the pump.
22. To remove the crosshead pin (23) from the crosshead (22), the assembly should be positioned on a
wooden fixture to avoid damage to crosshead. Drive out the pin on opposite side of mark located on the
crosshead. On those pumps without mark on crosshead, drive out pin by tapping on tapered side of pin.
23. To remove the bearing (15) remaining in the crankcase (1), insert small end of Giant bearing tool and tap
with a rubber mallet until bearing and seal (14) are completely removed.
The bearing can only be
removed from the inside by inserting the Giant Bearing Tool through the opposite side of the
crankcase.
The crosshead guide in the crankcase should be inspected for possible damage.
24. To reassemble, place the far bearing (15) in the crankcase (1) bearing housing and with the Giant Bearing
tool as a driver, tap into the crankcase using a rubber mallet.
25. Insert the far side crankshaft oil seal (14) with the Giant Bearing Tool making sure it is firmly seated and
well oiled. Always make sure that the crankshaft seal lip does not show signs of wear and that the garter
spring is firmly in place on the seal before reinserting into the pump. Replace the bearing cover (12) and
o-ring (13) and tighten securely.
