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Gear End Disassembly
14. Remove the crankcase cover bolts (9). Inspect the crancase cover O-ring (4) for wear. Replace if necessary.
15. Inspect the dip stick (5) vent hole for signs of clogging. Clean if necessary.
16. To remove the crankshaft (18), first remove the bearing cover plates (12) Remove the key (19).
17. 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 (18) from one side while turning it from the other side. The
turning insures that during this sequence the crankshaft does not become wedged agaisnt the connecting rods (20).
The far side bearing (15) will remain in the crancase (1). When free, the crankshaft (18) can be removed by hand.
18. The crankshaft bearing (15) remains on the crankshaft (18) as it is removed. The near side crankshaft seal (14) will be
removed by this procedure.
19. If necessary, use a bearing puller to remove crankshaft bearing (15).
20. Remove the connecting rod (20) and plunger rod/crosshead assembly (22) from the rear of the pump by pulling
straight out of the crosshead guides.
21. To remove the crankcase oil seal (26), tap oil seal out from the rear of the crankcase using a dowel and rubber mallet.
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 clips 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 pin (23) on opposite side of mark on the crosshead. On those pumps without
mark on crosshead, drive out pin by tapping on tappered side of pin.
23. To remove the bearing remaining in the crankcase, insert small end of Giant Bearing tool and tap with a rubber mallet
untill bearing and seal 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 (1) and should be inspected for possible damage.
Gear End Reassembly
24. To reassemble, place the far bearing in the crankcase bearing housing and with the Giant Bearing tool as a driver, tap
into the crankcase (1) 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 (14) lip does not show signs of wear. Replace the bearing cover (12) and
tighten securely.
26. Replace the connecting rod (20) and plunger rod/crosshead assembly (22) by press-fitting the crosshead pin (23).
Make sure to insert the beveled edge of the crosshead pin into crosshead. If the crosshead has a mark, install pin
frommarked side. The crosshead pin (23) should not extend beyond either side of the crosshead in order to prevent
damage to the crosshead bore of the crankcase.
27. Place each crosshead/plunger assembly (22) into the pump making sure that all of the parts are well oiled before
insertion into the crankcase.
28. Replace near side bearing on crankshaft (18) and mallet to tap into place.
29. Take the crankshaft (18) end with the bearing and insert the other end through the bearing housing carefully threading
the lobes of the crankshaft through the well lubricated connecting rods (20). Turning the crankshaft while tapping it
through the connecting rods will help prevent binding and possiable damage to the connecting rods. Continue
tapping the crankshaft through the connecting rods (20) until it is firmly seated into far side bearing.
30. Insert the near side crankshaft oil seal (14), making sure it is firmly seated and well oiled. Replace the bearing cover (12)
and tighten securely.
31. See instructions (13 above) for re-installing fluid end onto gear end.
32. Clean the back edge of crankcase and replace the crankcase cover. Be careful not to pinch the crankcase cover o-ring.
33. Fill the P46W crankcase with 8 oz. of Giant oil. and check the oil level with the dipstick. Proper level is center of two
lines Reinstall the pump into your system.
REPAIR INSTRUCTIONS - P46W, P46W-HK, & P46HT