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GP KFZ Series Repair Manual

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K K F F Z Z
Repair Manual

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Summary of Contents for GP KFZ Series

  • Page 1 K K F F Z Z Repair Manual...

  • Page 2: Table Of Contents

    KFZ SERIES GENERAL PUMP A member of the Interpump Group INDEX INTRODUCTION ..........Page 3 REPAIR INSTRUCTIONS .

  • Page 3: Introduction

    A member of the Interpump Group 1. INTRODUCTION This manual describes the instructions for repairing the KFZ 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 duration. General Pump declines any responsibility for damage caused by misuse or the non-observance of the instructions described in this manual.

  • Page 4: Crank Mechanism Disassembly

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 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.

  • Page 5: Crank Mechanism Assembly

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 2.1.2 Crank mechanism assembly After cleaning the crankcase, reassemble the crankcase mechanism as follows: A) Thoroughly fit the plunger guide seals into their seat on the crankcase as shown in fig. 5a using the proper tool (p/n F27904900).

  • Page 6: Disassembly/Assembly Of Bearings And Shims

    KFZ SERIES GENERAL PUMP A member of the Interpump Group Before assembling the cover (sight glass side), be sure that the shim rings have been inserted. To help the covers fit onto the crankcase, we advise using 3 screws M6 x 40, and then finish the operation with the screws supplied (M6 x 18) as shown in fig.
  • Page 7 KFZ SERIES GENERAL PUMP A member of the Interpump Group 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 5 ft. lbs. (7 Nm). To position the two side covers on the crankcase, initially use 3 screws, M6 x 40 as shown in fig.
  • Page 8 KFZ SERIES GENERAL PUMP A member of the Interpump Group 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.

  • Page 9: Fluid End Repair

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 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.

  • Page 10: Head Assembly - Valve Units

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 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.

  • Page 11: Disassembly Of The Head - Seals

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 2.2.3 Disassembly of the head - seals The replacement of the seals is necessary if water leaks are detected from the draining 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.

  • Page 12: Plunger Unit Disassembly

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 2.2.4 Plunger Unit Disassembly The plunger unit does not require periodic maintenance. Service interventions are limited to visual inspections only. For plunger unit extraction, operate as follows: A) Unfasten the M7 x 1 plunger screws as shown in fig. 20.

  • Page 13: Screw Calibration

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 13. SCREW CALIBRATION Exploded View Fastening Torque Fastening Torque Description Position (ft. lbs.) (Nm) Cover fastening screws Plunger fastening screws Connecting rod caps fastening screws Head fastening screws 44** 60**...

  • Page 14: Repair Tools

    KFZ SERIES GENERAL PUMP A member of the Interpump Group 4. REPAIR TOOLS Pump repair may be facilitated by using the proper tools. See Below. For Assembly: Basket Brush Øe 55; Alternative sealing ring H.P. Ø40 x 55 x 10...

  • Page 15: Maintenance Log

    KFZ SERIES GENERAL PUMP A member of the Interpump Group MAINTENANCE LOG HOURS & DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT GP Companies, Inc. 1174 Northland Drive Mendota Heights, MN 55120 Ref 300758 Rev.A Phone:651.686.2199 Fax: 800.535.1745 05-10 www.generalpump.com email: sales@gpcompanies.com...

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