Giant MP4120-SWS, Инструкция по эксплуатации / Руководство по ремонту и обслуживанию

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REPAIR INSTRUCTIONS - MP4120-SWS/MP4124-SWS
10
Gear End Disassembly
20. Remove the manifold and plunger assemblies as described earlier. Make sure the oil is drained
from the pump before removing the crankcase cover (#4). Remove all screws (#10). Inspect the
crankcase cover o-ring (#5) for damage and replace it as necessary.
21. Remove the connecting rod screws and washers with a 6mm allen wrench. Remove the back
halves of each connecting rod (#24) . Push the connecting rods down as far as possible into the
crankcase (#1) housing. Note that the connecting rod halves are numbered (or colored) and that
the numbers (or colors) must be matched for reassembly.
22. Remove the crankshaft bearing cover screws (#17) with a 13mm wrench. Remove the key (#23) from
the crankshaft (#22).
23. Remove the bearing cover (#14) and any shims (#20A) if any. Remember to replace shims on the
same side of the crankcase (#1) during the reassembly.
24. Steady the pump rear assembly and, using a rubber mallet, tap the crankshaft (#22) from one side.
The far side bearing race will be removed and the near side race will remain in the crankcase. The
roller bearings (#20) will remain on the crankshaft. When both ends are free, the crankshaft can be
removed by hand.
25. To remove the remaining bearing race, place a dowel against the inside edge of the race and tap it
out with a rubber mallet. This is done only if the race wear surface has been damaged.
26. Inspect the bearing race removed with the crankshaft (#22) and replace if wear surface is damaged.
27. Note: The following procedure is only necessary if the inspection shows evidence of heavy
wear. Inspect the crankshaft (#22) and bearings (#20) for wear. To remove the roller bearings from
the crankshaft, use a three inch push puller with a pulley attachment. To remount the bearings, tap
the bearings down the well-lubricated crankshaft with the Giant Bearing Tool. Be sure that the bearing
is firmly seated.
28. Remove the connecting rod (#24) with the attached crosshead/plunger assembly (#25) from the
crankcase (#1) by pulling it straight out. The oil seals (#31) may now be removed by tapping them
out through the front of the crankcase. Be careful not to damage the snap ring.
29. Inspect the surfaces of the crosshead/plunger assembly (#25) and connecting rods (#24) for heavy
scoring or galling due to poor lubrication. Check for play at the joint between connecting rod cross-
head/plunger assembly.
30. To remove the crosshead pin (#28) from the crosshead/plunger assembly (#25), the assembly should
be positioned in such a manner to prevent damage to the crosshead when driving the pin out. The
crosshead pin can be driven out by tapping on the tapered side of the pin.
Reassembly Sequence
Note: Always take time to lubricate all metal and nonmetal parts with a light film of oil before reassem -
bly. This step will help ensure a proper fit, at the same time it will protect the pump non-metal parts
(elastomers) from cutting and scoring.
31. Take the crosshead/plunger rod assembly and insert the connecting rod (#24) into the crosshead/
plunger assembly (#25). Drive the tapered end of the crosshead pin (#28) into the beveled side of
the crosshead and through the connecting rod completing the assembly.
Note: The crosshead pin should not extend beyond either side of the crosshead in order to prevent dam-
age to the crosshead bore of the crankcase.
32. Inspect the crankcase crosshead guides for any possible damage.
33. Replace the connecting rod (#24), crosshead/plunger rod assembly (#25) into the crankcase (#1).
34. If removed previously, replace the far side bearing race into the crankcase. Tap with a rubber mallet
until the edges are flush with the crankcase surface.
35. Remove the old crankshaft seal (#15) from the bearing cover (#14). Lubricate the edges of the new
seal and install using the standard Giant Bearing Tool. Remove the bearing tool and tap around the
perimeter of the seal with a rubber mallet to firmly seat the seal. Position the far bearing cover on the
crankcase (#1) and insert the cover bolts (#17). Tighten the cover evenly to the crankcase, setting the
bearing into position. Torque the cover bolts to 221 in.-lbs. (25 Nm).