General Pump KV Series Operating instructions

KV
Repair Manual
Ref 310084 Rev. A
08-17
8
General Pump
is a member of
the Interpump Group
KV12 - KV14

INDEX
1. INTRODUCTION ..................................................Page 3
2. REPAIR INSTRUCTIONS ...........................................Page 3
2.1 Crank Mechanism Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
2.1.1 Crank Mechanism Disassembly .............................Page 4
2.1.2 Crank Mechanism Assembly ...............................Page 6
2.1.3 Reduction Classes .......................................Page 10
2.2 Fluid End Repair ...............................................Page 13
2.2.1 Disassembly of the Head - Valve Units .......................Page 13
2.2.2 Reassembling the Head - Liners - Valves .....................Page 16
2.2.3 Disassembly of the Plunger Unit - Supports - Seals .............Page 16
2.2.4 Reassembly of the Plunger Unit - Supports - Seals..............Page 19
3. SCREW CALIBRATION ............................................Page 23
4. REPAIR TOOLS ..................................................Page 25
5. MAINTENANCE LOG ..............................................Page 26
Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 2

1. INTRODUCTION
This manual describes the instructions for repairing KV Series pumps, and must be carefully read and
understood before performing any repair intervention on the pump. Correct use and adequate maintenance is
fundamental for the pump’s regular operation and long wear. General Pump declines any responsibility for
damage caused by the misuse or the non-observance of the instructions described in this manual.
2. REPAIR INSTRUCTIONS
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, Fig. 1, and then the draining plug (2, fig. 1).
Exhausted oil must be collected in an appropriate receptacle and disposed of in
designated locations. In absolutely no case may it be disposed of in the environment.
Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 3

2.1.1 Crank Mechanism Disassembly
The operations described must be performed after removing the hydraulic part, ceramic pistons and
splash guards from the pump (par. 2.2.3, 2.2.4).
The correct sequence is the following
Disassemble:
• Pump shaft key
• Rear cover
• The con-rod as follows: unscrew the cap fixing screws, remove the con-rod caps with their
lower half-bearings (fig. 2) paying attention to the numbered sequence during disassembly.
To avoid possible errors, caps and con-rod shanks have been numbered on one side (1, fig. 2/a)
Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
• Side covers using 3 fully threaded M6 x 50 screws, inserting them in the threaded holes as
indicated in fig. 3.
Page 4

Page 5
Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
• Push the plunger guides forward with their con-rods to facilitate side extraction of the pump
shaft as shown in fig. 4.
• Remove the pump shaft
• Complete disassembly of the con-rod units by removing them from the crankcase and
removing the plunger guilde pins.
• Remove the pump shaft seal rings using standard tools.
• Remove the plunger guide seal rings as described below:
Use the extractor hammer (#F26019400) (1, fig.5) and the pliers (#F27503800) (2, fig. 5).
Insert the gripper as far as possible onto the seal ring with the aid of a hammer(fig. 5/a), sub
sequently screwing the extractor to the gipper, and use the extractor hammer (fig. 5/b) until the
ring to be replaced is removed (fig. 5/c).

Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 6
2.1.2 Crank Mechanism Assembly
After cleaning the crankcase, reassemble the crankcase mechanism as follows:
• Assemble the upper and lower half-bearings in their seats in the con-rods and caps.
Make sure that the reference marks on the upper half- bearings (1, fig. 6) and
lower half-bearing (2, fig. 6/a) are positioned in their respective seats in the con-
rod and cap.

Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 7
• Insert the plunger/con-rod guide units into the crankcase, directing the numbering on the
con-rod shank towards the top of the casting.
To facilitate pump shaft insertion (without the key), it is essential to repeat the operation performed
during disassembly, pushing the plunger/con-rod guide units as far down as possible
(paragraph. 2.1.1).
• Before assembling the side cover on the PTO side, check the conditions of the radial ring lip
seal and relative contact area on the shaft.
If replacement is necessary, position the new ring using a tool (#F27904500) as shown in fig. 7
If the pump shaft shows diametrical wear in the area of contact with the lip seal, in order
to prevent the grinding operation, it is possible to reposition the ring in abutment with
the cover as shown in fig. 7.
Before assembling the side covers, make sure there are O-rings on both of them and shim rings on the
indicator side cover only.
To facilitate filling of the first section and relative press fitting of the covers on the crankcase, we recommend
using 3 partially-threaded M6 x 40 screws (1, fig. 8), then completing the operation with screws supplied
(M6 x 16).

Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 8
• Couple the con-rod caps to their shanks, referring to the numbering (1, fig. 9).
Not the correct assembly direction of the caps.
• Fasten the caps to their repective con-rod shanks by means of M8 x 1 x 48 screws (fig. 10)
lubricating both the underhead and the threaded shank, proceeding in two different stages:
1. Manually turn the screws until they begin to tighten.
2. Tightening torque 22.13 ft lbs (30 Nm)
Alternatively, ensure:
1. Pre-tightening torque 7.38-11.06 ft lbs (10-15 Nm)
2. Tightening torque 22.13 ft lbs (30 Nm)

Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 9
• After having completed tightening operations, check that the con-rod head has a side
clearance in both directions.
• Insert the new plunger guide seal rings as far as possible into the relative seat on the
crankcase (fig. 11), following the procedure described:
Use tool (#F27904200) composed of a tapered bush and buffer. Screw the tapered bush into
the hole in the plunger guide (fig. 11/a), insert the new seal ring on the buffer as far as it will
go (determined by the height of the buffer) into its seat on the crankcase (fig. 11/b), remove
the tapered bush (fig. 11/c).
• Mount the rear cover complete with O-ring, positioning the dipstick hole upward.
• Insert oil in the casing as indicated in the Owner’s manual.

Ref 310087 Rev. A
08-17
KV SERIES
GENERAL PUMP A member of the Interpump Group
Page 10
2.1.3 Reduction Classes
TABLE OF REDUCTION FOR CRANKSHAFT AND CON-ROD HALF-BEARINGS
Recovery classes
(mm)
Upper half-bearing
code
Lower half-bearing
code
Grinding on the shaft pin diameter
(mm)
0.25 F90922100 F90922400 Ø39.75 0/-0.02 Ra 0.4 Rt3.5
0.50 F90922200 F90922500 Ø39.50 0/-0.02 Ra 0.4 Rt 3.5
2.1.4 Assembly / Disassembly of bearings and shims
The type of bearings (taper roller) ensures the absence of axial clearance on the crankshaft. The shims are
defined to meet this necessity. For disassembly / reassembly and for any replacements, carefully observe the
following directions:
A) Assembly / Disassembly of the crankshaft without replacing the bearings
After removing the side covers, as indicated in paragraph 2.1.1, check the rollers and their races for wear; if
all parts are in good condition, fully clean the components with a suitable degreaser and grease them again
evenly using the same oil in the crankcase. The same shims can be used again, being careful to insert them
only under the indicator side cover. After installing the complete unit (sight glass side flange, shaft and engine
side flange), check that the shaft’s rolling torque - with the connecting rods free - is at least 3 Ft. Lbs. (4 Nm),
Max 4.5 Ft. Lbs. (6 Nm). To position the two side covers on the crankcase, initially use 3 M6 x 40 screws as
shown in fig. 8, and then the fastening screws. The shafts rolling torque (with connecting rods coupled must
not exceed 6 Ft. Lbs. (8 Nm).
B) Disassembly / Assembly of the Crankshaft With Bearings Replacement
After disassembling the side covers as indicated in paragraph 2.1.1, remove the outer ring nut on the
bearings from its seat on the covers, using an appropriate exctrator as shown in (fig. 12 and 12/a).
Remove the inner ring nut on the bearings from the two ends of the shaft, again using an appropriate
extractor or, alternatively, a simple “pin punch” as shown in fig. 13.