General Pump KEZ Series Operating instructions

KEZ
Repair Manual
Ref 300666 Rev. B
03-18
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
Page 2
INDEX
1. INTRODUCTION ..................................................Page 3
2. REPAIR ISTRUCTIONS ............................................Page 3
2.1 Crank Mechanism Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.1.1 Crank mechanism disassembly ...........................Page 4
2.1.2 Crank mechanism assembly .............................Page 4
2.1.3 Disassembly/Assembly of bearings and shims ...............Page 6
2.2 Fluid End Repair ...............................................Page 9
2.2.1 Disassembly of the head - valve units......................Page 9
2.2.2 Head assembly - valve units .............................Page 10
2.2.3 Disassembly of the head - seals ..........................Page 11
2.2.4 Plunger unit disassembly................................Page 13
2.2.5 Head assembly - seals - plunger unit ......................Page 13
3. SCREW CALIBRATION ............................................Page 14
4. REPAIR TOOLS ..................................................Page 14
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
2. REPAIR INSTRUCTIONS
1. INTRODUCTION
This manual describes the instructions for repairing the KEZ Pump, and must be carefully read and understood before
performing any repair intervention on the pump.
Correct use and adequate maintenance is fundamental for the pumps regular operation and long duration. General
Pump declines any responsibility for damage caused by misuse or the non-observance of the instructions described in
this manual.
2.1 Crank Mechanism Repair
Crank mechanism repair operations must be carried out after draining the oil from the crankcase. To
drain the oil, remove the oil dipstick (1), and then the plug (2), in fig. 1.
Exhausted oil must be collected in an appropriate container and disposed of in appropriate
locations. In absolutely no case may it be disposed of in the environment.
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fig. 1

GENERAL PUMP A member of the Interpump Group KEZ SERIES
Page 4
2.1.1 Crank mechanism disassembly
The correct sequence is the following:
A) Dissasemble:
• pump shaft key
• rear cover
• connecting rod cap
• side covers, using 3 wholly threaded M6 x 50 screws, inserting
them in the holes as shown in fig. 2.
B) Push the plunger guides and connecting rods forward in order to facilitate the lateral extraction of the
crankshaft.
NOTE: to extract the plunger guide it is necessary to remove the ceramic plunger and wiper first.
C) Disassemble the crankshaft oil seals and the plunger guides using standard tools.
2.1.2 Crank mechanism assembly
A) Fit the oil seals of guide plungers in the crankcase by sliding them all the way inside until they correctly
seat in place (see fig. 5a). The use of the tool #F27904200 will facilitate the task.
B) Introduce the pre-assembled plunger guide/connecting rod units into their seat; to facilitate tightening
of the connecting rod cap, we advise to position the connecting rod so you can easily read the number.
To easily introduce the crankshaft, without the key, fully push in the plunger guide/connecting rod unit,
as indicated in section B, paragraph 2.1.1, and shown in fig. 4.
fig. 2
fig. 4
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
Page 5
B) Before reassembly of the side covers, check the seal lips for wear. If replacement is necessary, position
the new ring using the correct tool (#F27904500) as shown in fig. 5.
If the shaft presents diameter wear corresponding to the sealing lip, to avoid the need for griding it’s
possible to position the ring as indicated in fig. 5.
To help the covers fit onto the crankcase, we advise to use 3 screws, M6 x 40, and then finish the
operation with the screws supplied (M6 x 18) as shown in fig. 6.
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
Page 6
D) Install the connecting rod cap respecting numbering, and fasten the relevant bolts (lubricating both the
head and the threaded stem) proceeding in three different steps, see fig. 7.
1. Approaching torque 4-6 ft. lbs. (6-8 Nm)
2. Pre-fastening torque 18-20 ft. lbs. (25-28 Nm)
3. Fastening torque 28 ft. lbs. (38 Nm)
E) After setting the torque, check that the big end of the connecting rod has a lateral play in both directions.
F) Install thr rear cover positioning the oil dipstick hole upward.
G) Fill the crankcase with oil as indicated in the owner’s manual paragraph 7.4
2.1.3 Disassembly / Assembly of bearings and shims
The type of bearings used (taper roller bearings) ensures the absence of axial play on the crankshaft; the
shims are to be determined to reach this purpose. Tp disassemble/assemble, or to replace them if needed,
carefully follow the instructions below.
A) After removing the side covers, as indicated in paragraph 2.1.1, check the rollers and their faces for wear;
if all parts are in good condition, accurately clean the components with a suitable degreaser and grease
them again evenly using the same oil used in the crankcase.
The same shims can be used again, being careful to fit them under the cover on the sight glass side. After
installing the complete unit (sight glass flange + shaft + engine side flange), check that the shaft’s rolling
torque - with the connecting rods free - is a least 3 ft. lbs. (4 Nm), max 4 ft. lbs. (6 Nm). To position
the two side covers on the crankcase, initially use 3 screws, M6 x 40 as shown in fig. 6, and then
fastening the screws.
The shaft’s rolling torque (with the connecting rods coupled) must not exceed 6 ft. lbs. (8 Nm).
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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B) Disassembly/assembly of the crankshaft with bearing replacement
After disassembling the side covers as indicated in paragraph 2.1.1, remove the outer ring nut of the
bearings from their covers and the inner ring nut, with the remaining part of the bearing, from the two shaft
extremeties using a standard pin extractor or similar tool as indicated in figures 8 and 9.
fig. 8
fig. 9
The new roller bearing can be mounted at room temperature with a press or fly press; it is necessary to lay
them on the lateral side of the relevant ring nuts with correct rings. The driving operation can be facilitated
by heating the relevant parts at a temperature ranging between 2500-3000F (1200-1500C), making sure
that the ring nuts are correctly fitted into their seats.
Never invert the parts of the two bearings.
The shim pack must be redefined as follows:
A) Insert the crankshaft in the crankcase, being sure that the P.T.O. shank comes out of the correct side.
B) Fit the P.T.O. side flange to the crankcase paying great attention to the seal lip as indicated in paragraph
2.1.2, section C.
C) Position the flange on the sight glass side as indicated in paragraph 2.1.1.
D) Use a thickness gauge (see fig. 10).
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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Determine the shim pack as indicated in the table below.
fig. 10
Measurement Shim Type # Pieces
From: 0.05 to: 0.10 / /
From: 0.11 to: 0.20 0.1 1
From: 0.21 to: 0.30 0.1 2
From: 0.31 to: 0.35 0.25 1
From: 0.36 to: 0.45 0.35 1
From: 0.46 to: 0.55 0.35
0.10
1
1
From: 0.56 to: 0.60 0.25 2
From: 0.61 to: 0.70 0.35
0.25
1
1
E) Insert the shims under the cover on the sight glass side (see fig. 11), fixing it to the crankcase using the
appropriate screws, and verifying that the stall torque is between 3-4 ft. lbs. (4-6 Nm).
F) If the torque values is correct, connect the rods to the crankshaft; other wise, redefing the shims again
repeating the operations from point “C”.
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
2.2 Fluid End Repair
2.2.1 Disassembly of the head - valve units
Service operations are limited to valve inspection or replacement if needed.
To extract the valve units proceed as follows:
A) Unfasten the 7 M12 x 35 valve cover screws, and remove the cover (fig. 12).
B) Remove the valve plugs with an M6 threaded bolt (fig. 12).
C) Remove the valve assemblies with a pliers to grab the valve cages (fig. 12).
Should excessive scaling stick the valve seats down in the manifold (for example after
inactivity for long period) then the use of the extractor tool #F26019400 is recommended
(see fig. 12a).
fig. 12
fig. 12a
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2.2.2 Head assembly - valve units
Pay careful attention to state of wear of the various components; replace them when necessary, and
in any case within the intervals indicated in the table in fig. 14, Chapter 11 of the Owner’s Manual.
At each inspection, replace all valve units and valve plugs OR rings and enti-extrusion rings.
Before repositioning the valve units, clean and perfectly dry the relevant seats in the head as
indicated in fig. 14.
GENERAL PUMP A member of the Interpump Group KEZ SERIES
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Disassemble the valve assemblies with simple tools - a couple of screw drivers (fig. 13) would work more than fine.
Components valve assemblies are pressed together with a minimal load, therefore the job results extremely
easy to be carried out. Being the valve cages are made of polymer, attention should be taken during service in
order to prevent the cage ribs from being damaged.
fig. 13
fig. 14
Proceed with reassembly by inverting the proceedure indicated in paragraph 2.2.1.
During the assembly of the suction and delivery valve units (fig. 15 - fig. 16) do not invert the suction
springs with the previously disassembled delivery springs:
a) Suction springs “white”
b) Delivery springs “black”
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
Page 11
To facilitate the insertion of the valve guide into its seat, use a tube that lays on the horizontal shoulders of
the guide (fig. 16a and use a hammer acting on the entire circumference.
fig. 15 fig. 16 fig. 16a
Insert the suction and delivery valve units checking that they are thoroughly inserted in the head seat.
Therefore apply the valve covers and proceed with calibrating the related M10 x 25 screws with a torque wrench as
indicated in Section 3.
2.2.3 Disassembly of the head - seats
The replacement of the seals is necessary if water leaks are detected from the drain holes located at the rear of
the crankcase, and in any case within the intervals indicated in the table in fig. 14, Chapter 11 of the Owner’s Manual.
A) Unfasten the M10 x 110 head screws as shown in fig. 17.
fig. 17
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Pay careful attention to the order of sealing pack disassembly as shown in Fig. 19, composed of:
1) Packing Retainer
2) O-ring
3) Low Pressure Packing Ring
4) Intermediate Ring
5) High Pressure Packing Ring
GENERAL PUMP A member of the Interpump Group KEZ SERIES
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B) Remove the head from the crankcase.
C) Extract the high pressure seals from the head, and the low pressure seals from their related support by
using standard tools as shown in fig. 18; be careful not to damage the seals.
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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2.2.4 Plunger Unit Disassembly
The plunger unit does not require periodical maintenance. Service interventions are limited to visual
inspections only. For plunger unit extraction, operate as follows:
A) Unfasten the plunger screws as shown in fig. 20.
fig. 19
B) Check for wear; replace if necessary.
At each disassembly, all plunger unit O-rings MUST be replaced.
2.2.5 Head assembly - seals - plunger unit
Reassemble the various components by inverting the operations previously listed in paragraph 2.2.3, paying careful
attention to the following:
A) Seal packing: respect the same order followed during disassembly.
B) Lubricate components 3 and 5 with silicone grease type (#F12001600) on outer diameter only.
C) Fore correctly assembling the HP and LP seals in their related seats on the head, use the correct tools as
indicated in Section 4.
D) Reassemble the plungers by fastening the screws with a torque wrench, respecting the fastening torque
value inicated in Section 3.
E) Assemble the head: for fastening torque values and fastening sequences, follow the instructions in Section 3.
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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13. SCREW CALIBRATION
Description Exploded View
Position Material Fastening Torque (ft. lbs.)
Fastening Torque
(Nm)
Cover fastening screws 9Stainless Steel 7 10
Plunger fastening screws 28 8.8 15 20
Connecting rod caps
fastening screws 16 12 R 28* 38*
Valve cover screws 36 Stainless Steel 26** 35**
Head fastening screws 35 Stainless Steel 26*** 35***
Service plug 51 Nickel Plated Brass 30 40
* The connecting rod caps fastening screws must be tightened respecting the phases indicated in “Point D”
of page 6.
** The valve cover screws, exploded view position 36, must be fastened using a torque wrench, respecting
the order shown in the schematic in fig. 21.
*** The head fastening screws, exploded position 35, must be fastened using a torque wrench, lubricating
the threaded stem, respecting the order shown in the schematic in fig. 21.
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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4. REPAIR TOOLS
Pump repair may be facilitated by using the proper tools. See Below.
For Assembly:
Packing Insertion Guide, HP, Dia. 36 x 48 x 8 F27465800
F26406300
Packing Insertion Guide, LP, Dia. 36 x 42 x 15 530083
Pump Shaft Oil Seal Stopper F27904500
Plunger Guide Oil Seal Stopper F27904200
For Disassembly:
Suction/Delivery Valves and Seats F26019400
F27513700
Plunger Guide Oil Seal F26019400
F27503800
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GENERAL PUMP A member of the Interpump Group KEZ SERIES
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MAINTENANCE LOG
OIL CHANGE
GREASE
PACKING
REPLACEMENT
PLUNGER
REPLACEMENT
VALVE
REPLACEMENT
HOURS & DATE
GP Companies, Inc.
1174 Northland Drive
Mendota Heights, MN 55120
Phone:[phone] Fax: [phone]
www.generalpump.com email: [email protected]
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